PIM International March 2015 DP

Vol. 9 No.
1 MARCH 2015
in this issue
Carbon control in MIM
MIM at GKN Sinter Metals
PIM at Euro PM2014
Published by Inovar Communications Ltd www.pim-international.com
Publisher & editorial offices
Inovar Communications Ltd
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Managing Director and Editor

Nick Williams
Tel: +44 (0)1743 454991 For the metal, ceramic and carbide injection moulding industries
Email: nick@inovar-communications.com
Publishing Director
Paul Whittaker
Tel: +44 (0)1743 454992
Email: paul@inovar-communications.com
Consulting Editors
Clear enthusiasm for MIM

Professor Randall M German
Associate Dean of Engineering, Professor of
Mechanical Engineering, San Diego State
amongst product designers

University, USA
Dr Yoshiyuki Kato
Kato Professional Engineer Office, Yokohama, Japan
Professor Dr Frank Petzoldt In most issues of PIM International we run a selection of news items
Deputy Director, Fraunhofer IFAM, Bremen, Germany
on new applications for MIM and CIM. These stories typically reach
Dr David Whittaker
DWA Consulting, Wolverhampton, UK us because a product developer has become so excited by the PIM
Bernard Williams process and what they have been able to achieve with it that the tech-
Consultant, Shrewsbury, UK nology becomes a major part of their product marketing campaign.
Advertising Whilst the examples of new applications in this issue range from high
Jon Craxford, Advertising Director
Tel: +44 (0) 207 1939 749 volume mass market products to the extremely niche, the fact that
Fax: +44 (0) 1743 469 909 PIM technology is being used as a unique selling point can only help
E-mail: jon@inovar-communications.com make more designers and engineers aware of the potential of the
Subscriptions process.
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Accuracy of contents
Whilst every effort has been made to ensure the readers around the world who previously would not have had access
accuracy of the information in this publication, to up-to-date information on the technology and its applications.
the publisher accepts no responsibility for errors The fact that many of these readers are potential end-users of PIM
or omissions or for any consequences arising
there from. Inovar Communications Ltd cannot be technology has, as can be seen in this issue, had the effect of making
held responsible for views or claims expressed by ever more parts makers see PIM International as a viable promotional
contributors or advertisers, which are not necessarily channel for their businesses.
those of the publisher.
Advertisements
For readers of this issue of PIM International who are considering PIM
Although all advertising material is expected to for a new application, or considering setting up a PIM operation, then
conform to ethical standards, inclusion in this the European Powder Metallurgy Associations PIM Short Course,
publication does not constitute a guarantee or
endorsement of the quality or value of such product
Barcelona, April 15-17, will be a unique opportunity to learn from, and
or of the claims made by its manufacturer. network with, key figures from some of the industrys leading part
manufacturers and suppliers.
Reproduction, storage and usage
Single photocopies of articles may be made for
personal use in accordance with national copyright
Nick Williams
laws. All rights reserved. Except as outlined above, Managing Editor
no part of this publication may be reproduced or
Worldwide transmitted in any form or by any means, electronic,
Global manufacturer of nodular and spherical aluminum powders, photocopying or otherwise, without prior permission
of the publisher and copyright owner.
pre-alloyed aluminum powders, and aluminum premixes for PM
www.ampal-inc.com www.poudres-hermillon.com Design and production
Cover image
In the Americas Printed by MIM parts entering a Cremer
Supplier of carbonyl iron and atomized stainless steel powders for Cambrian Printers, Aberystwyth, United Kingdom Thermoprozessanlagen GmbH
MIM-Master sintering furnace in
the MIM and PM industries ISSN 1753-1497 (print) GKN Sinter Metals Bad Langensalza
MIM plant, Germany
ISSN 2055-6667 (online)
United States Metal Powders, Incorporated
408 U.S. Highway 202, Flemington, New Jersey 08822 USA Vol. 9. No. 1 March 2015
Tel: +1 (908) 782 5454 Fax: +1 (908) 782 3489 2015 Inovar Communications Ltd
email: rhonda.kasler@usbronzepowders.com March 2015 Powder Injection Moulding International 1
YOUR ONE-SOURCE for | contents page | news | events | advertisers index |
March 2015
METAL INJECTION MOLDING
Rapid Prototyping through Mass Production
11 25 32 44 58
In this issue
31 Carbon Control: An important discriminant 63 Magnesium PIM for biomedical applications
in Metal Injection Moulding Dr David Whittaker reviews a paper presented at
The challenge of carbon control strongly influenced Euro PM2014 by Martin Wolff, Helmholtz-Zentrum
the early development of MIM technology and still Geesthacht (HZG), Germany, discussing the viability
Complex precision components.

today it is recognised as one of the fundamental of processing medical implants from magnesium
factors influencing final component quality. Prof alloys by PIM. Magnesium is of particular interest for
Randall German, San Diego State University, USA, medical implant applications thanks to its excellent
reviews the history of carbon control in MIM and biodegradability and biocompatibility.
analyses the relevant reactions that take place
during the MIM processing cycle. 69 Microstructural studies of advanced PIM
materials
43 GKN Sinter Metals: Process automation In our final report from Euro PM2014 Dr David
enables growth in automotive applications Whittaker reviews two papers which report on
It has been eight years since PIM International last microstructural studies of two advanced PIM
visited GKN Sinter Metals Bad Langensalza plant in materials, namely metal-ceramic interpenetrating
Germany, one of Europes largest MIM operations, phase composites and HK-30 stainless steel.
and much has happened in the industry in the
ISO 9001:2008-Certified
intervening period. Dr Georg Schlieper reports on 75 Low volume and prototype MIM
From concept through design and development, to prototypes and, finally, mass ISO/TS 16949-Certified the development of MIM in Bad Langensalza and the components using green machining and
production, ARCMIM utilizes advanced manufacturing technologies to provide full-service, AS 9100-Certified opportunities that lie ahead. sinter joining
ISO 13485-Certified
quality solutions with accelerated timelines. The rapid production of small quantities of MIM
51 Advances in the MIM of titanium
components is of increasing interest to producers
As a full-service MIM provider, ARCMIM offers its customers the convenience, efficiency, quality The Euro PM2014 conference, which took place in worldwide. In this study Shinya Sakurai, Kazuaki
and cost advantages inherent with a one-source partner. As a MIM veteran and technology Salzburg, Austria, September 21-24, presented an Nishiyabu and Shigeo Tanaka report on the
leader ARCMIM ensures the precision, ingenuity, product efficacy and superior quality necessary invaluable opportunity for the industry to review development of a novel MIM process involving
in todays competitive marketplace. We support and provide our customers with: progress to-date on global developments relating the sinter-joining of components produced by the
> Metal injection molding to the MIM of titanium. Dr Thomas Ebel, from machining of green MIM compacts.
Helmholtz-Zentrum Geesthacht (HZG), Germany,
> Plastic injection molding
Regular features
reports on a selection of key presentations from the
> Magnesium injection molding event, including those with a focus on biomedical and
> Medical cleanroom molding dental applications, Metal Matrix Composites and
> 3D printing in metal and plastic complex 3D structures. 5 Industry news
> State-of-the-art tool center 80 Events guide, Advertisers index
> Custom hermetic seals, flanges and fittings
> World-class facilities in USA and Europe
Vol. 9 No. 1 2015 Inovar Communications Ltd March 2015 Powder Injection Moulding International 3
Contact usthe
Discover today! Europe:
ARCMIM +36 35 551
Advantage 000 United
Contact States: 303-833-6000
us today! www.arcmim.com
| contents page | news | events | advertisers index | | contents page | news | events | advertisers index | Industry News
Industry News
To submit news for inclusion in Powder Injection Moulding International please contact Nick Williams, nick@inovar-communications.com
Partners Group acquires Partners Group, we have the strategic support and capital
backing to enter into the next phase of growth for our
Dynacast company.
Joel Schwartz, Managing Director at Partners Group in
Partners Group, a global private markets investment New York, stated, Dynacast already has a truly differenti-
manager, has acquired a controlling stake in Dynacast ated position as a global supplier in the precision metal
International on behalf of clients. The transaction was components marketplace and we see exciting potential
reported to have an overall enterprise value of $1.1 billion for further expansion. We believe our global platform and
and closed on January 30 2015. deep network of industry relationships make us the ideal
Dynacast International is a global manufacturer of partner to back managements vision for the business
small, highly complex metal components using its propri- going forward, particularly through our assistance with
etary precision die-casting and Metal Injection Moulding acquisitions and with the deepening of the companys
(MIM) technologies to produce customised, high-volume integrated, worldwide approach.
components with complex shapes and tight tolerances. www.dynacast.com
The company, which was profiled in the December 2014
issue of PIM International, is headquartered in Charlotte,
North Carolina, USA, and has 23 manufacturing plants in
16 countries worldwide. These serve a diverse client base
including blue-chip customers across the automotive,
telecommunications, computing, consumer electronics,
and healthcare industries.
Dynacast was acquired in 2011 by a consortium
of investors including Izurium Capital Management,
WCapital Partners, Laurel Crown Partners, Kenner
& Company, Babson Capital Management, Macquarie
Capital and some members of management. Since its
acquisition in 2011, the company has expanded its foot- C
print and penetrated new markets with its broad range ofM
product offerings while strengthening its product portfolio
Y
with its recent acquisition of US-based MIM producer
Kinetics Climax Inc. CM
Partners Group acquired Dynacast from exiting finan-MY

cial investors and is joined in the acquisition by Kenner
CY
& Company, an existing shareholder, and the companys

management team, which will both roll over significant CMY
equity stakes into the new transaction. It was stated K
that Partners Group and Kenner & Company will work

closely with Dynacasts management team to support the
company in the next phase of its global growth plans.
Simon Newman, Chief Executive Officer of Dynacast,
stated, Dynacast has a long and rich history of continu-
ously refining our proprietary manufacturing technolo-
gies, in-house tooling expertise and innovative design
processes to manufacture highly complex metal compo-
nents in a fast, repeatable and precise manner to provide
greater value to our customers. With the investment led by
4 Powder Injection Moulding International March 2015 2015 Inovar Communications Ltd Vol. 9 No. 1 Vol. 9 No. 1 2015 Inovar Communications Ltd March 2015 Powder Injection Moulding International 5
Industry News | contents page | news | events |Industry
advertisersNews
index | | contents page | news | events | advertisers index |
MIMSandvik
and CIMOsprey
parts used in Cochlear
appoints new Business Smartwatch
INTRODUCING ELNIKS
hearing implant devices
Development Manager for the Americas market heats up TM
Cochlear Gas atomised
is one MIM leaders
of the world powder producersound vibrations, via the
time to find theskull,
right directly
person for Alcatel OneTouch,
in advanced hearing
Sandvik technologies
Osprey, based in Neath, to the functioning cochlea.
the role and were delighted that a brand belonging
with headquarters in Macquarie
UK, has announced Park,
that Mary Kate The company
Mary Katerecently introduced
is joining the Sandvik to Hong Kong
Sydney, Australia,
Johnstonand hasadditional
joined the Company itsas
Baha BP100
Ospreysound
team.processor
Mary Kates role will listed TCL
manufacturing
Powders facilities
GroupinBusiness
Gothenburg, which it states
Develop- sets a new
complement salesbenchmark
and marketing Communication,
Sweden. Cochlear implants, first
ment Manager for the Americas.inThis hearing aid performance. Key to
activities in other regions of the world launched its new
introduced in the early 1980s, have the the design of the Baha BP100 is the
important appointment, stated the from her Scranton base and ensure smartwatch at
ability to restore hearing for individuals use of MIM technology which allows
company, will support the continued that we are attuned to the needs of this years CES
who are severely hard of hearing and
growth of the metal powder
Cochlear to produce the unique shape
business, our customers
for whom conventional hearing aids are and tolerances required for the two in North and South show in Las The Alcatel CUTTING EDGE TECHNOLOGICAL ADVANCES THAT CAN SAVE YOU THOUSANDS $$
regarded
of little help. as strategically important America and continue
outer shell casings used in the chassis to deliver Vegas. The watch OneTouch watch
for the Sandvik Group. high quality
The company states that the implant of the sound processor. Titanium was products and The
excellent snap coupling
case is and abutment
reported of the of
Martin Kearns, Sandvik the Cochlear Baha BP100 The Metal Injection Molding process can be both risky and very costly unless you have a company like Elnik Systems
device bypasses damaged hair cells Ospreys customerofservice.
selected because its biocompatibility to be manufactured by MIM.
Powder
in the inner ear, orGroup
cochlea, which told PIMand light weight,
Director, yet italready
Johnston is a strong
hasand11 years of The race to develop new smart- working with you. The reason is simple. For over 18 years, Elnik Systems has made technological innovation its
stimulateInternational
the hearing nerve directly.
, It has taken somestable material. The MIM
experience with titanium
Sandvik US in the hearing implants,
watches is, thehowever,
feedthrough, at the
revealing cornerstone. And innovative thinking leads to smarter MIM performance, we call MIM-telligenceTM.
For example, the Baha system devel- parts aresales
said to have
and stood up of
marketing specialistthe PM2010
well Powder
threat Metallurgy
of competing World
technologies to
oped by Cochlear combines a sound in all the metal
18 reliability tests,
products, even in strip CongressMIM,
primarily in Florence.
which has This is the
traditionally been a
processor with an abutment and a challenging environments. The design mechanical structure that provides the Taking it a step further, once Elnik innovates, extensive field testing is done before their new technology hits the market
and wire products for automotive, core technology for watch cases. It has
small titanium implant with the implant of the Baha BP100 combines the use electrical connection for the platinum
consumer and medical markets been reported that Lenovo and Huawei with the help of the full-sized production furnaces at DSH Technologies LLC, a research and development sister
being placed behind the non-func- of the Europlug and the Cochlear Baha pins in and out of the device housing.
among others. Kearns stated that her have both recently launched smart-
tioning ear. It takes around 3 months fitting software to allow direct audio Biocompatibility and long term implan- company of Elnik. Elnik also offers free DSH services for one year with the purchase of each new piece of
for the implant to osseointegrate with knowledge of the
input from MP3 players, phones andmetals industry will phones
tation stability asusing
well as chassis manufactured
mechanical
the bone. The Baha sound processor be advantageous
other audio sources. in understanding using metal-stamping,
and electrical functionality are some and Apple their equipment, providing every Elnik customer with additional customized technical support and dependability.
may then be attached to the implant customer requirements
Cochlear also reported the use of and of the requirements that had to besmart
identi- states that its new 316L met watch Another Elnik MIM-telligenceTM benefit.
abutment via a snap coupling. The fying powder
ceramic injection mouldedmetallurgical
Al2O3 in one solutions. caseAlis2Ocold
with the CIM 3
forged.
feedthrough.
Sandvikthe
implant ensures Ospreys
optimal Mary KateofJohnston
transfer of the most critical components in its
www.smt.sandvik.com www.cochlear.com
www.alcatelonetouch.com
INNOVATIVE SYSTEM FEATURES
AccuTemp proprietary thermocouple control
resulting in tight temperature control
Automatic Cleaning Features of binder

trapping components and Dry Vacuum Pump.
ColdFinger Debind Trap forced flow

enhanced binder trapping.
Gas Tight Retort Design Superior gas control

throughout process zone, eliminating escaping
gas as compared to competitive designs.
Laminar Gas Flow efficient and effective gas

management for debinding and sintering.
Simple Ease of Use PLC controls via Excel

spreadsheet.
Vol. 56No.Powder
1 Injection
Inovar MouldingLtd
Communications International
MarchMarch
2011 2015
Powder Injection Moulding
2015 Ltd Vol. 9 No.
International
Inovar Communications 91 107
Vol. 9Commerce Road
No. 1 2015 Inovar | Cedar
Communications Ltd Grove, NJ 07009
March 2015 USA | +1.973.239.6066
Powder | www.elnik.com
Injection Moulding International 7
Industry News | contents page | news | events | advertisers index | | contents page | news | events | advertisers index |
EPSON ATMIX CORPORATION

Japanese MIM producer seeks The latter parts are produced using
a mixture of a special space holder
production partner in Europe agent mixed with standard metal
powders and binder. The mixture
Taisei Kogyo Co Ltd, one of Japans The company uses its own in-house is injection moulded, debound and
leading producers of Metal Injection developed feedstock and moulding sintered to form the required porous
Moulded (MIM) parts, is seeking a technology and supplies MIM parts to structure.
production partner in the European a range of markets including camera Dr Shigeo Tanaka, President
Union. The prospective partner and related precision equipment of Taisei Kogyo, believes that the
will be expected to have technical industries, industrial machinery, company is one of only a few MIM
knowledge and experience of MIM automotive, IT, microelectronics, producers that is capable of offering
manufacturing and to possess some medical devices and robotics. a wide range of materials combined
MIM manufacturing equipment. Micro MIM is one of the companys with high dimensional accuracy and
Taisei Kogyo specialises in the specialities, producing parts from complicated shape components.
development and production of small, stainless steel, titanium, copper, The company already has customers
highly complex MIM parts and micro nickel and tungsten mainly for in Europe, including Austria, Italy
MIM parts. The company is seeking microelectronics but also for and Germany, but it believes that by
a partner who will either undertake
some aspects of the MIM processing,
or who will cooperate in the develop-
cameras such as a tiny 17-4PH
stainless steel MIM part weighing
just 0.007g. Other specialities are
cooperating with a European partner
it can broaden its MIM knowledge Finer Powder Production
and expertise with new applications.
ment of the complex moulds required
for small MIM parts.
composite MIM parts where the
injection moulding process is used to
The company would also be keen
to cooperate with the partner in the
Cleaner Powder Production
Taisei Kogyo, which was profiled
in the June 2008 edition of PIM
over-mould plastic substrates, multi-
layer MIM parts involving different
reciprocal development of European
MIM production know-how in Japan. Shape Control of Powders
International, has been involved in metals and porous metal and micro- Further details can be obtained from:
MIM production for around 15 years porous metal components using shigeo_tanaka@taisei-kogyo-net.co.jp
and micro MIM parts for ten years. proprietary space holder technology. www.taisei-kogyo.com/en/
Low Alloy Steel

High Alloy Steel
Stainless Steel
Magnetic Materials
Granulated Powder
JAPAN
Mr. Numasawa, Ryo
Numasawa.Ryo@exc.epson.co.jp U.S.A and SOUTH AMERICA
Mr. Pelletiers, Tom
ASIA and OCEANIA tpelletiers@scmmetals.com
Mr. Yoshida, Shunsuke
yoshida-s@pacificsowa.co.jp EU
Dr. Pyrasch, Dieter
CHINA Dieter.Pyrasch@thyssenkrupp.com
Mr. Ota, Arata
ota-a@pacificsowa.co.jp KOREA
8 Powder Injection Moulding International March 2015 2015 Inovar Communications Ltd Vol. 9 No. 1 Vol. 9 No. 1 2015 Inovar Communications Ltd Mr. Moulding
March 2015 Powder Injection Yun, John
International 9
dkico@hanafos.com
Industry News | contents page | news | events | advertisers index | | contents page | news | events | advertisers index | Industry News
Carbolite and Gero announce merger showcase the companys range of

furnaces.
Revolutionary eyewear hinge High Temperature
and North American distribution It was also announced that, as to use MIM technology Furnaces up to 3,000 C
a result of the merger, Geros high
Carbolite GmbH, the German and under different atmospheres will temperature and vacuum furnace Metal Injection Moulding (MIM) technology has been
sales organisation of the British be part of the offering, as well as high systems will be available in North used for the production of the small, high strength
company Carbolite Ltd., and Gero temperature furnaces with tungsten, America for the first time. Verder components for eyewear hinges for many years, enabling
Hochtemperaturfen GmbH & Co. KG molybdenum or graphite insulation. Scientific, Inc., the United States popular innovations such as sprung hinges. MIM
have announced that as of January Both companies are part of the Dutch subsidiary of Verder Scientific under technology has now been adopted for a new generation
2015 the companies will merge to Verder Group. Following the merger which Carbolite Gero operates, now of revolutionary eyewear hinges designed by Italian
form Carbolite-Gero GmbH & Co. KG. the production area at the companys offers Retsch, Carbolite and Carbolite designer Guido Medana.
The new company offers furnaces Gero equipment with fully trained Medanas SPINE hinge is a result of his lifelong
Based on more than
headquarters in Neuhausen, near
that operate from 30C to 3000C. Stuttgart, will be increased. A new product managers to address all career in engineering and it is claimed to be the ultimate 30 years of heat
Systems for applications in vacuum customer centre is also planned to inquiries. solution to hinge design in the optical world. Inspired treatment experience
Michael Hager, Product Manager by the interaction between vertebrae, SPINE solves Carbolite Gero offer
at Verder Scientific Inc., told PIM age-old hinge limitations. Typical optical hinges have standard products as
International, With over 30 years dead points, meaning they are either open or shut, with well as customer-
of furnace manufacturing under nothing in-between. They do not naturally have give.
specific solutions.
the direction of Roland Geiger, This limits comfort and increases fragility. In solving this
Gero is a well-established furnace issue, the SPINE design gently flexes to fit any head size,
manufacturing company in the lightly gripping the face. There are no screws used in the n Furnaces for MIM
European Union and is excited to offer working mechanism, so nothing to loosen, and due to and CIM production
its products to the North American the dual spring and cable the temples shut automatically and quality testing
market. Gero furnaces are commonly when removed from the face.
n Thermal or catalytic
used in Europe by companies in the There are five working SPINE vertebrae, constantly
debinding without
aerospace, chemical, energy, and interacting seamlessly with each other to create a 90
the need for
advanced materials sector as well as hinge opening. As every element helps the other to
condensate traps
research and academia. take the strain they rotate only 18 degrees, meaning
The company offers PIM furnaces they share the load, making wear from friction virtually n Sintering furnaces
that can operate with thermal or non-existent. These vertebrae are made by MIM from under partial
catalytic debinding systems without stainless steel. pressure or low
the need for condensate traps. SPINE stated that, The MIM method can produce overpressure
www.carbolite.com | www.gero- parts where it is difficult, or even impossible, to efficiently
gmbh.de | www.verder-scientific.us manufacture these items by any other means. This
ability to combine several typically prohibitive operations
into one fluid process ensures MIM provides numerous
Carpenter reports measurable savings, not only in the reduction of lead
Q2 results times but also the evasion of multiple processes usually

amplified by miniaturisation. But MIM is recognised as
a green technology thanks to the significant reduction
Carpenter Technology Corp has
in wastage compared to traditional manufacturing
announced net sales of $548.4 million
methods, such as 5 axis CNC machining.
for the second quarter of its fiscal
www.spineoptics.com
year 2015 (ending December 31 2014),
an increase of $44.9 million from the
same quarter last year.
Operating income was $45.0
million, down $2.5 million from the
second quarter of the prior year.
The reduction in operating income
was stated as being due to the
Reading press outage in November,
higher SAO operating costs, and the
additional depreciation expense of the
Athens facility, which were all partially
offset by lower variable compensa-
www.carbolite-gero.com
tion expense and a stronger mix of Phone: +49 (0) 7234 9522-0
products.
www.cartech.com Details of the SPINE MIM hinge
10 Powder Injection Moulding International March 2015 2015 Inovar Communications Ltd Vol. 9 No. 1 Vol. 9 No. 1 2015 Inovar Communications Ltd March 2015 Powder Injection Moulding International
Gero-Advert-GB-PM-105x297.indd 1
11
22.01.2015 15:46:06
North American distributor named for Strategic MIM heat sinks boost copper
Chinese nickel powder producer partnership powder production in China
Canadian New Energy/Electronic million lbs. capacity from the market, announced in eye China has in the past decade seen annual growth rates
Materials Corporation (Cnem), based Jinchuan recently commissioned wear sector of around 25% for the production and consumption of
in Mississauga, Ontario, Canada, a new carbonyl facility. The plants copper and copper base powders. According to an article
has been appointed North American annual output is expected to exceed 10 IDEAL S.r.l, an Italian manufacturer by Jingguo Zhang, et al (Beijing General Research Institute
distributor for Jinchuan Group, Chinas million lbs. and provide the ability to of high-precision micro mechanical for Nonferrous Metals and GRIPM Advanced Materials)
largest nickel producer. Cnem is expand nickel powder sales beyond the components for the eye wear published in Powder Metallurgy (Vol. 57, No. 5, December
responsible for sales of the groups Chinese domestic market. Markets sector, has chosen Italian Metal 2014), China produced around 45,000 tonnes of copper and
carbonyl nickel powders. for Cnems powder include MIM, PM, Injection Moulding (MIM) specialist Cu-base powders in 2012 which represents 40% of the
The company stated, Seizing upon batteries and fuel cell electrodes. MimestSpA as a partner to develop worlds total. Europe is said to have 25% of global market
the withdrawal of Norilsk and its 8 www.cnemcorp.com products for its core markets. share, North America 20% and the rest of the world 15%.
Mimest is a MIM company with a Main application areas for Cu powders include diamond
long track record serving high tech tools, friction materials, carbon brushes, self-lubricating
markets. Mimests Matteo Perina bearings, structural PM components and MIM parts.
told PIM International, Mimest In terms of tonnage consumption of Cu and Cu-based
shares a vision with IDEAL based powders for the individual areas in China, diamond tools
on R&D and innovation. With our used around 9,000 tonnes in 2012, followed by friction
ten years of experience in MIM materials at 5,000 tonnes, carbon brushes (mainly
serving such markets as biomedical, electrolytic grades) 4,000 tonnes, and Cu powder used in
industrial and automotive we have MIM at around 4,500 tonnes. The main MIM application
advanced expertise in processing a is for heat sinks (or heat pipes) produced at a number
MIM debind and sinter wide materials portfolio including

difficult to process materials such as
of plants in China and also Taiwan. Production routes
for copper powders in China include electrolysis (ten
vacuum furnaces
titanium alloys. producers), water and gas atomisation (>50 producers),
IDEAL, with its 40 years hydrometallurgy, and crushing/grinding.
of experience in machining www.gripm.com
Over 6,500 production and laboratory furnaces manufactured since 1954 technologies, has a dedicated
design team capable of developing
micromechanical parts of any type High visitor numbers
Metal or graphite hot zones
Processes all binders and
and complexity, and benefits from expected at Chinas leading
feedstocks
a department dedicated to the
complete in-house construction PM exhibition
Sizes from 8.5 to 340 liters of machinery and moulds for the
(0.312 cu ft.) The annual PM China event has steadily grown in recent
production of such parts.
Pressures from 10-6 torr to years and 2015s event promises to be the largest and
Perina stated, This partnership
750 torr most successful in the series to-date. The 2015 China
between IDEAL and Mimest
Vacuum, Ar, N2 and H2 (Shanghai) International Powder Metallurgy Exhibition
is characterised by significant
Max possible temperature and Conference takes place from April 27-29 in Shanghai,
synergistic values and places IDEAL
3,500C (6,332F) China.
as the leader in the spectacle
Worldwide field service, The event, which attracts key international industry
market for the supply of high-tech
rebuilds and parts for all suppliers as well as a huge number of specialist Chinese
MIM parts, including parts with any
makes companies, has been boosted by the ongoing and rapid
necessary machining and finishing
growth in both conventional Powder Metallurgy and Metal
operations.
MIM-VacTM We can now integrate the
Injection Moulding in China.
In addition to the large trade exhibition, a parallel
Injectavac capabilities of Mimest, such as
mould design and MIM production,
symposium will see presentations from a number of
international materials and technology suppliers.
with those of IDEAL in mould
PM Chinas Maggie Song told PIM International,
production and machining. As a
Market demand for PM and MIM remains strong in China
result IDEAL is able to offer its
and the demand for upgrading technology is even stronger.
customers in the eyewear sector
Centorr Vacuum Industries, Inc. We invite the international community to join us at PM
55 Northeastern Blvd best in class performance for both
Nashua, NH 03062 China to find out what you can do to meet growing market
product development and production
USA demand, as well as the right solutions and partners.
Tel: +1 603 595 7233 lead times.
For more information email Maggie Song at
www.centorr.com/pi Fax: +1 603 595 9220
Email: sales@centorr.com
www.mimest.com | www.ideal.it
pmexpochina@163.com or visit the event website.
www.cn-pmexpo.com
005-08-14 CRS_CPP_AD_Resize_vs2bOL.indd 1 8/21/14 10:15 AM
Industry News | contents page | news | events | advertisers index | | contents page | news | events | advertisers index |
Indias Defence Minister introduced to

MIM and PM at PMAI conference
Indias Defence Minister, Manohar to Meeturaj Industries. It is reported
Parrikar, received a detailed that the company will specialise in
introduction to Metal Injection watch cases, textile machinery parts,
Moulding (MIM) and Powder power tools and hardware.
Metallurgy (PM) technology at the Bollina told PIM International,
Indias Defence Minister, Manohar
recent PM15 International Conference The defence sector has tremendous
Parrikar (left) with N Gopinath (centre)
on Powder Metallurgy and Particulate potential to adopt MIM components.
and Dr Ravi Bollina (right)
Materials & Exhibition, January 19-21, It is our endeavour to promote MIM
Mumbai. The event was organised by as a leading technology for the
the Powder Metallurgy Association of manufacture of complex small and
India (PMAI). medium size components on a mass
President of the PMAI, N Gopinath, scale. This is in line with the Make
toured the exhibition with the minister in India initiative announced by the
during which time he was introduced Indian government. MIM is poised
to one of the countrys newest MIM to become a dominant technology
producers, Meeturaj Industries, based in India and there is ample room for
in Gujarat. This company, which new entrants to cater to the growing The LechTech stand at PM15
started production in September market in India and globally.
2014, was established with the Make in India is a marketing signed agreements with several firms
technical support of Dr Ravi Bollina, campaign slogan coined by the Prime to provide turnkey MIM solutions,
LechTech Materials Pvt. Ltd, a MIM Minister of India, Narendra Modi to as well as a turnkey solution for the
and PM consultancy provider for the attract businesses from around the production of stainless steel powders
Indian and Asian market. LechTech world to invest and manufacture in in India.
provided a complete turnkey solution India. LechTech states that it has www.lechtechmaterials.com
HIGH QUALITY On the leading edge of

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14 Powder Injection Moulding International March 2015 2015 Inovar Communications Ltd Vol. 9 No. 1 Vol. 9 No. 1 2015 Inovar Communications Ltd March 2015
www.smt.sandvik.com/metalpowder Powder
e-mail: Injection Moulding International
powders.osprey@sandvik.com
15
GREENLONG Vacuum furnace manufacturer TAV

celebrates 30th anniversary
Hybrid kneading, mixing and pelletizing machines
for in-house PIM feedstock production
In late 2014 Italys TAV (Tecnologie
Alto Vuoto), a leading manufacturer of
vacuum furnaces, celebrated reaching
SmartPower
its 30th anniversary. TAVs manage- servohydraulic excellence
ment told PIM International, We
Single solution for kneading, mixing and pelletizing without material transfer
are celebrating our 30th anniversary
Control the length and surface smoothness of pellets now because the official day of the
Automatic temperature control during the mixing process founding of the company was the A HM5 vacuum furnace from TAV
December 21st 2014. Our celebrations
Efficient and stable performance, with manual and automatic modes
will extend throughout 2015. customer satisfaction, has been in
Servo control system and easy-clean chamber Since 1984 TAV has produced place since 1998 to ensure the highest
Powder and gas collection system more than 640 vacuum furnaces, manufacturing quality of its vacuum
operational in over 45 countries and furnaces.
Wear resistant barrel and screw five continents. TAV stated that it TAV customers come from a wide
High torque screw design for feedstock flow continuously develops its technology spread of industries and include MIM
and vacuum furnaces through a close specialists, major aeronautic and
collaboration with its customers aerospace companies and advanced
and partners. The companys quality heat treatment centres.
system, which is strongly focused on www.tav-vacuumfurnaces.com
25 120 t
New powder alloy is as light as

aluminium and as strong as titanium
Two teams of researchers from North low density that is, as far as we can
Carolina State University and Qatar tell, unmatched by any other metallic
University have developed a new
high-entropy metal alloy that has a
material. The strength-to-weight ratio
is comparable to some ceramics, but generous
higher strength-to-weight ratio than we think its tougher and less brittle
any other existing metallic material. than ceramics.
High-entropy alloys are materials We still have a lot of research to
that consist of five or more metals do to fully characterise this material
in approximately equal amounts. and explore the best processing compact
These alloys are currently the focus methods for it, added Koch. At
of significant attention in materials this point, the primary problem
science and engineering and the with the alloy is that it is made of
research teams have been successful 20% scandium, which is extremely efficient
in combining lithium, magnesium, expensive. Due to the high vapour
titanium, aluminium and scandium to pressures of several of the elements
make a nanocrystalline high-entropy (Li, Mg), the researchers used
alloy that has low density, but very mechanical alloying to prepare the
high strength. alloy powders instead of melting
The density is comparable to and casting. The elemental metal
aluminium, but it is stronger than powders, of better than 99% purity,
titanium alloys, stated NC States were obtained from Alfa Aesar.
Professor Carl Koch, who is the The mechanically alloyed powder,
senior author of a paper on the which did not have the high N, O
work titled A Novel Low Density, impurity levels, was observed to have
High Hardness, High-Entropy Alloy a single-phase fcc crystal structure Headquarters:
with Close-packed Single-phase in the as-milled condition. It had a WITTMANN BATTENFELD GmbH
Nanocrystalline Structures, nanocrystalline grain size estimated Wiener Neustdter Strae 81|A-2542 Kottingbrunn
Tel.: +43 (0) 2252 404-0|Fax.: +43 (0) 2252 404-1062
published in the journal Materials by the Scherrer formula to be about
info@wittmann-group.com
Research Letters. It has a 12 nm.
combination of high strength and www.ncsu.edu | www.qu.edu.qa
Qingdao Greenlong Machinery Co., LTD
1809, 29 Building, Zhengyang East Country, Zhengyang Middle Road,
www.greenlong.cn
Chenyang District, Qingdao, Shangdong, China
Powder
16 81155768
TEL: +86 532 Injection
FAX: Moulding
+86 532 81155645 Email:International March
qd_greenlong@163.com 2015 Vol. 9 No. 1
2015 Inovar Communications Ltd Vol. 9 No. 1 2015 Inovar Communications Ltd March 2015 Powder Injection Moulding International 17
Metal Additive Manufacturing: A new

free download
Avure opens isostatic pressing
Vol. 1 No. 1 SPRING 2015

THE MAGAZINE FOR
THE METAL ADDITIVE
MANUFACTURING INDUSTRY
from the www.

magazine for the 3D printing of metals metal-am.com application centre in Sweden
website in late
Metal Additive Manufacturing, a e-newsletter, also wish to have April 2015. Swedens Avure Technologies, a evaluate the latest in HIP technology,
new quarterly magazine for the access to more in-depth information The printed leading manufacturer of ultra-high such as quenching under full
metal Additive Manufacturing (AM) on technical and commercial edition will be pressure systems, has established a pressure.
industry, will be launched by Inovar advances in the AM industry in a available by in this issue state-of-the-art application centre to Traditionally, HIP has been used
Communications Ltd in April 2015. format that they can save, either subscription,
DESIGNING FOR METAL
assist fabricators utilising advanced for densification, but the trend is now
AM
AM IN THE NETHER
LANDS
CEIT CRANIAL IMPLAN
TS
Available in both print (ISSN 2057- digitally or in print, for future as well as materials in the development of hot to combine densification with solution
Published by Inovar Communication
s Ltd
www.metal-am.com
Untitled-3 1
26/01/2015 16:14:38
3014) and digital (ISSN 2055-7183) reference, stated Nick Williams, from Inovar and cold isostatic pressing (HIP, treatment, quenching, ageing and/
formats, Metal Additive Manufacturing Inovars Managing Director. Communications stand at the CIP) applications. The new facility, or other heat treatment processes in
will bring together industry news and Inovar Communications is an Additive Manufacturing with Powder adjacent to Avures manufacturing the same cycle, explained Avures
articles on technical and commercial established publishing house with Metallurgy (AMPM) Conference, May plant, is equipped with two HIP Peter Henning, Business Unit
developments in the industry. The over twelve years of experience in the 18-20, San Diego, USA, and the RAPID presses and one CIP press. HIP tech- Director-AMD. This leads to signifi- Avures isostatic pressing application
publication of this new magazine metal powder processing industries. 2015 Conference and Exhibition, May nology produces parts with excellent cant savings in lead-time, improved centre in Vsters, Sweden
follows the successful launch of the Existing magazines include PM 18-21, Long Beach, USA.) isotropic material properties, offering product quality, and lower costs and
www.metal-am.com website in May Review and PIM International. For editorial enquiries the highest possible density of all energy savings resulting from fewer after testing.
2014. As with our sister publications, contact Nick Williams (nick@ available compaction methods. transports and re-heating. With vigorous development of new
This new high quality quarterly our aim is to not only provide relevant inovar-communications.com) or The Application Center allows us The application centre CIP has a manufacturing techniques in the
magazine will specifically focus coverage of the industry for those Paul Whittaker, (paul@inovar- to collaborate further with component working pressure up to 1,200 MPa, HIP arena, such as near-net shape
on developments in the Additive currently involved in it, but to promote communications.com). For fabricators in areas such as Addi- while the HIPs have a working range for Powder Metallurgy, MIM, and
Manufacturing of metals. We have the benefits of metal AM to a global advertising enquiries contact Jon tive Manufacturing, Metal Injection up to 207 MPa and 2000C. These especially Additive Manufacturing,
launched the title in response to audience of component producers and Craxford, Advertising Sales Director, Moulding and Investment Casting to presses are equipped with either Henning expects Avures application
feedback from industry professionals, potential end-users, stated Williams. jon@inovar-communications.com. ensure they select the best pressing Uniform Rapid Cooling (URC) or centre to become an integral part
who, whilst appreciating the The launch issue of Metal Additive www.metal-am.com systems to match their needs, Avures proprietary Uniform Rapid of component fabricators process
advantages of our existing Manufacturing will be available for stated Jan Sderstrm, CEO of Avure Quenching (URQ) capability, which optimisation and testing. It will be
Technologies AB. We can help them permits cooling rates of >3000C per an important, cost-effective step
verify their fabrication processes minute to be achieved. before parts manufacturers invest in
and determine parameters for cycle Having a well-equipped centre new equipment or enter full-scale
optimisation before they go into for testing has proven to be a very production, he stated.
full-scale production. powerful tool in discussions with When not engaged in customer
Currently hosting projects related prospective adopters of HIP tech- testing, the centres capacity is
to densification (defect healing) and nology, added Henning. Additionally, used for university or research
the removal of residual porosity in we offer services to evaluate the institute projects exploring new HIP
Investment Castings, the Application chemical composition, porosity, and applications.
Centre provides the opportunity to mechanical properties of materials www.industry.avure.com
Jiangxi Yuean Superfine Metal Co., Ltd YUELONG GmbH US Distributor

Tel: +86 797 8772 869 Fax: +86 797 8772 255 Tel: +49 6074 9147 933 United States Metal Powders, Inc.
Xinhua Industrial Park, Dayu County, b.li@yueanmetal.com Contact: Rhonda Kalser
Jiangxi Province rhonda.kasler@usbronzepowders.com
www.yueanmetal.com Tel: +1 908 782 5454
Simulation of powder/binder separation part rejection is powder-binder

segregation, which occurs during
delivering a basis for decisions on
part and mould design and avoiding Kyoto set to host APMA2015
optimises watch clasp production the moulding stage. Currently, costly iterations later on. Regions international conference
segregation defects are only with low particle concentration
Sigma Engineering GmbH, based particle concentration produced in discovered at the end of the are regions where particles have The Japan Society of Powder and Additive Manufacturing and Novel PM
in Aachen, Germany, has reported Sigmasoft Virtual Molding predicts production process when the parts segregated and where aesthetic or Powder Metallurgy, along with Processing. The technical programme
that its PIM simulation software is low concentration regions, where are sintered. At this point, the chance functional failure may occur in the the Japan PM Association, have will cover PM materials, compaction
now able to simulate powder-binder powder-binder segregation will lead to recycle the feedstock has been lost. PIM application. published a Call for Papers for and consolidation (including CIP and
segregation. This valuable tool to quality issues that may be visible Sigmasoft states that its software The first breakthrough in PIM APMA2015, the 3rd International HIP), sintering and post processing,
enables PIM processors to identify on the surface after secondary allows for a prognosis on how simulation was achieved four years Conference on PM in Asia. The powder forging, PIM, spray forming,
potential quality issues before a operations such as polishing. mould design, process parameters, ago, when models were implemented event will take place in Kyoto from spark plasma sintering, PM
mould is even built, reducing part Sigmasoft stated that one of feedstock and part design influence to accurately reproduce the feedstock November 8-10, 2015. production management and PM
rejection and increasing profitability. the most common reasons for local particle concentrations, thus flow. Research was done in modelling As well as a comprehensive materials. The abstract deadline is
The newly developed model the rheological, thermo-physical and technical programme, a special March 31, 2015.
considers the combined influence solidification properties of a wide interest programme will focus on www.apma2015.jp
of shear rate gradients, viscosity, range of MIM feedstocks. Back then,
particle concentration and shear rate gradients were identified
temperature gradients, thus as the main driving force for particle
delivering a reliable prediction of segregation.
the areas where quality issues may This shear-based segregation
arise. In the case study shown in Fig. model worked well for low particle
1, particle concentration in a watch content. However, it was found that
band clasp manufactured by French in feedstocks where the particle
PIM specialist Alliance is shown. content rises to levels between 55%
Because of the application, the part and 65%, the closely packed particles
has very high requirements regarding Fig. 1 Prediction of particle concentration in a watch clasp, identifying regions impair movement. In regions where
surface appearance. The result of where powder-binder segregation takes place the particle density increased, the
shear induced would not be enough
to produce segregation, as a particle
15
in a 20
would be restricted in movement
PM Ch i
by its neighbours. Therefore, ha
Shang 015
it was discovered that, besides A pril 2
27-29
shear, additional effects relating to
particle concentration would affect
segregation.
Particle concentration also affects
the melt viscosity. In powder-poor
regions the viscosity is low and,
as the particle content increases,
the viscosity increases following a
power-law correlation. Therefore,
in areas such as the centre of the
flow channel, the viscosity can reach
very high levels, while the feedstock
still flows smoothly at the channel
boundaries.
PM Tooling System
These correlations are The EROWA PM tooling system is the standard
incorporated in the simulation, so that interface of the press tools between the
in the future a back-coupling between
viscosity and particle segregation toolshop and the powder press machine.
is taken into account - the particle Its unrivalled resetting time also enables
segregation affects the filling pattern,
and thus the green part quality you to produce small series protably.
and the viscosity affects particle
segregation. As a consequence, www.erowa.com
the accuracy of the feedstock flow
prediction is also improved.
www.sigmasoft.de
SIMTech focuses on PIM of dissimilar KIT develops industrial scale PIM

materials and parts with complex production process for tungsten parts
internal features Tungsten is the material of choice for tungsten with titanium carbide or
the reactor wall surface of the Inter- yttrium oxide enables the tuning of a
The Powder Processing team within over injection moulding of dissimilar
national Thermonuclear Experimental wide range of mechanical properties
the Forming Technology Group at the materials to produce multi-functional
Reactors (ITER) successor DEMO. such as ductility and ultimate tensile
Singapore Institute of Manufacturing or composite parts has achieved
The divertor, where plasma impurities strength. Traditional joining methods
Technology (SIMTech) has in recent parts which have combined magnetic Fig. 1 Microstructure at the boundary/ and ash from the fusion process are such as brazing would require
years considerably enhanced its and non-magnetic properties, parts interface of the porous and solid removed, is exposed to extreme heat dedicated materials for the brazing
expertise in Powder Injection with high toughness combined with sections of the porous/dense CIM and particle fluxes. Tungsten is able to process. To overcome this problem
Moulding (PIM). Examples have high hardness and parts combining part, shown inset (From presentation withstand such high heat stress, but KIT researchers have developed a
included the development of new porous and solid materials. by Li Tao: Powder Injection Moulding it is difficult to process. The metal is 2-component PIM process which
binders and a better understanding One example cited by Dr Li was of dissimilar materials and complex extremely brittle and, therefore, tradi- enables joints to be produced in the
of the fundamentals of PIM binder the combination of Fe2Ni and 316L internal features, 2014) tional machining methods such as components without any additional
formulations, effect of chemical stainless steel which was said to
milling or turning are time consuming materials. KIT is currently developing
compositions on powder mixing, achieve good bonding at the interface sand casting could be produced by
and expensive. the PIM process further with respect
development of composite and during sintering. Another example is over-moulding to achieve the required
PIM offers an alternative and to producing doped materials and
dissimilar materials, optimising an over-moulded ceramic part having complex internal channels.
researchers at the Karlsruhe Institute with regard to its suitability for mass
the properties of the interfaces in a porous core and a dense surface SIMTech has also been striving to
of Technology (KIT) in Germany have production.
over-moulded PIM components, (Fig. 1). Dr Li stated that ceramic develop cost effective manufacturing
over the last five years successfully The tungsten parts produced by
the production of PIM components and metal PIM parts have also been technology for the mass production
adapted the PIM process to be used KIT have undergone heat flux tests
having complex internal features or developed using proprietary sacrificial of 316L microMIM parts and
with tungsten. They produced parts at FZ Jlichs electron beam facility
channels and micro Metal Injection material to form the complex internal parts with micro features such as
from a micro gearwheel 3 mm in JUDITH-1. Thermal shock and
Moulding. features or channels in the sintered microstructure arrays using special
diameter and with a weight of just thermal fatigue tests have shown
Dr Li Tao, leader of the Powder parts. He stated that a metallic closed binder formulations.
0.050 g, and plate shaped parts up to promising results. The next step will
Processing team, stated that the pump impeller normally produced by www.simtech.a-star.edu.sg
a 1.4kg with dimensions of 60 x 60 be studies with respect to plasma-
x 20 mm. Thus the researchers not wall-interaction. Divertor parts manu-
only demonstrated the suitability of factured for ASDEX Upgrade will be
EMBEMOULD
the PIM process for tungsten, they tested there in 2015. Other PIM parts
also showed its scalability and its are also being investigated at the test
ability to produce complex shapes with rig GLADIS at the Max-Planck-Institut
great precision. Another advantage fr Plasmaphysik (IPP).
of PIM tungsten parts is the isotropic Steffen Antusch at KIT stated that
MIM feedstock | MIM & CIM binders characteristic of all material proper-
ties. Parts machined from plates or
rods do not feature such uniaxial grain
the flexibility of the PIM process allows
a variety of new designs and shapes
to be produced on an industrial scale.
orientation and therefore do not offer The tungsten PIM monoblocks will
At eMBe we have the products and services EMBEMOULD C AND EMBEMOULD K 83 full placement flexibility. be assembled into a divertor element
to help you shape up your metal or ceramic MIM and CIM binders for water and solvent debinding Another issue for DEMO is the and proposed for tests in the WEST
powders, from binders for solvent and catalytic joining of tungsten-materials using experiment in France.
debinding to ready-to-mould feedstock. EMBEMOULD FEEDSTOCK different doping methods. Doping Email: steffen.antusch@kit.edu
MIM feedstock for solvent or catalytic debinding
Develop your products with us by using our in-
house laboratory and extensive experience as EMBELUBE
one of Europes leading PM additive suppliers. Poreformers for PIM products with porosity
Our services focus on product development and

product innovation to continuously meet our
customers evolving needs worldwide.
eMBe Products & Service GmbH

Gemeindewald 7, 86672 Thierhaupten, Germany
Tel.: +49 8271 421988-3 Fax: +49 8271 421988-4
servicepoint@embe-products.com
www.embe-products.com KIT researchers have produced various tungsten components using Powder
Embemould and Embelube are registered trademarks. Photo Arburg GmbH & Co KG
Injection Moulding (Image: KIT, Tanja Meiner)
Down to 10 Microns
MIM technology finds niche in
Superfine Stainless Steel MIM Powders audiophile headphone housings
for the Most Demanding Applications Metal Injection Moulding is being
used by headphone manufacturers
to create complex headphone
combined housing pieces are then
hand finished with a textured,
brushed appearance to the stainless
Innovative & Advanced Metallurgical Technology housings that offer users significantly
improved listening experiences. UK
steel.
Whilst the RHA headphones
Fig. 1 RHA Audios T10i
based headphone manufacturer retail for around $200, audiophile

More than 25 years ago, AMETEK developed a RHA has introduced its flagship T10i headphones by Japans Final Audio
proprietary method of producing and processing headphone (Fig. 1), featuring the Design can retail for up to $2500.
fine metal powders for our customers exacting worlds first ergonomic, stainless In Final Audios products, MIM has
specifications. Today, our ongoing commitment to steel driver housings for the mass enabled the freedom to design and
market. The housing comprises manufacture internal forms that have
innovative and advanced metallurgical technology,
two sections of injection moulded considerable influence on sound
and the ability to offer customized formulations, stainless steel (Fig. 2). quality, controlling elements such Fig. 2 T10i housings in the green (left)
grades, and sizing (even down to 10 microns), RHA states that MIM was the as resonance and air flow. The back and sintered/polished state (right)
makes AMETEK your industry choice. only way it could have achieved the of Final Audios Heaven VIII design,
ear contoured shape of the T10i in shown in Fig. 3, is reported to not
Austenitic Stainless Steel durable stainless steel. Not only is only be for decoration, but resonance
316L used in applications which require good the T10i designed for comfort, but it dispersion has also been factored into
corrosion resistance, strength, and ductility. Also is also has unique sonic and airflow the design, making for a high-level
available in 304L, 310L, and 347L. properties ideal for functioning with balance between beauty and function.
the T10is handmade dynamic driver. In 2014 FloMet LLC, an ARCMIM
Ferritic Stainless Steel Following injection moulding, Company, won an MPIF award for a
430L ferritic stainless steel combines good magnetic the parts are solvent and thermally group of MIM headphone components Fig. 3 Final Audios Heaven VIII
response and some corrosion resistance. Also debound prior to sintering. The for US-based Sure Inc. headphone with MIM housing
available in P410L, P434L, P409, and P420.
17-4PH Precipitation Hardening Stainless Steel
This precipitation hardening grade stainless is used
to obtain strength and hardness. It offers better
corrosion resistance than 400 series stainless steel.
The World Class Technologies
A range of properties and hardness can be achieved out of Japan
through heat treatment.
Nickel & Cobalt Alloys Total Solu)on Supplier from Materials to Finished parts
High-temperature and corrosion-resistant components Sintered parts : AlN, Ti-6Al-4V and other dicult materials
for energy, medical and high performance engine Feedstocks : Improves Quality and ProducGon Eciency
applications now require these MIM alloy materials. Binders : Full-Mould Thermal only de-binding system
Step up to the world class quality Aluminum Nitride heat sink

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Tel: +1 724-225-8400 Fax: +1 724-225-6622
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Improve rejecGon rate
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www.ametekmetals.com Higher dimensional accuracy minimizes secondary processes By thermal only de-binding system
www.atect.co.jp
9001:2008 pimsales@atect.co.jp
C E R T I F I E D
error of 0.191 mm. The reason was

PIM offers savings for Material NAK80 Fe-0%Ni Fe-2%Ni Fe-5%Ni Fe-8%Ni
that the first MIM parts produced
Manufacturing
large bicycle transmission Process
Cutting Powder Injection Molding showed a lower total part volume
of 3012 mm3 when using the 60:40
components UTS [MPa] 1264 1244 1347 1356 1419 powder/binder ratio in comparison
HV 391 349 403 416 468 with the 3D modelling of the original
The Powder Injection Moulding (PIM) process has, machined adapter part at a total
since its introduction in the early 1980s, been used Table 1 Comparison of mechanical properties of materials used to produce
volume of 3160 mm3.
primarily to mass-produce small parts of less bicycle adapter hub.
The researchers were able to
than 10 mm in diameter. Now researchers at the rectify the dimensional errors by
Ultimate Manufacturing Technology Center, Korea In solvent debinding, the during sintering was a uniform 18%. modifying the mixing ratio of the
Institute of Industrial Technology (KiTech), Daegu, specimens were treated with hexane As can be seen in Table 1 metal powder and binder to make up
have successfully used PIM technology to produce at 40C for 1 h followed by removal the Fe-2%Ni powder alloy came for the deficient volume of the part.
a relatively large adapter part for the internally of the wax substance when the closest in terms of mechanical The mixing ratio of powder to binder
geared hub of a bicycle. The PIM process offers temperature was increased to 400C properties to the NAK80 steel used was changed to 63:37 and following
significant advantages compared to the same part under vacuum. In thermal debinding, in machining, reaching around injection moulding of this feedstock
made by machining steel, including 100% material the remaining polymer was removed 1350 MPa ultimate tensile strength mixture a total part volume of
utilisation compared with only 19.6% for machining, a in a nitrogen atmosphere at a and 8% elongation. This alloy was 3176mm3 was achieved. The
reduction in manufacturing hours from 78 to 26 and temperature between 400C and therefore selected to produce the dimensional change of the modified
five manufacturing steps in PIM compared with six in 1,000C. After debinding, a vacuum MIM adapter parts of the same adapter part was thereby reduced
machining. was created to remove the remaining size as the machined hub-type to 0.116 mm at the upper section of
Jin Woo Jeon and colleagues stated in their paper binder inside the sintering furnace internal gears of a bicycle (Fig. the tooth surface and 0.09 mm at
published in Key Engineering Materials (Vols. 622-623, and sintering was conducted in 1). However, whilst there were no the lower section thereby meeting
(2014), pp 868-875) that an iron-nickel alloy containing a nitrogen atmosphere for 3 h at cracks or distortion visible with the dimensional tolerance specifications
varying amounts of Ni was used to produce test 1330C. The sintered parts were naked eye, 3D scanning of the MIM for the adapter part. Fig. 2 shows
pieces for the adapter part. The Fe-Ni alloy system finally heat treated at 930C for adapter part showed a maximum the shape of the upper section after
was found to be the closest in mechanical properties 1 h by an oil quenching process, dimensional error of 0.301mm for modifying the mixing ratio of powder
to those of NAK80, a popular machining grade steel. and tempered at 380C for 1.5 h. the upper tooth surface and the and binder in the PIM feedstock.
PIM feedstock using an organic binder from BASF Shrinkage rate of the MIM parts lower tooth surface showed a size www.kitech.re.kr
and a Fe-Ni powder:binder ratio of 60:40 was injection
moulded in a vertical motor-operated machine from
Nissei, followed by subsequent 2-stage solvent and
thermal debinding.
CM Furnaces, long recognized as an industrial leader in performance-proven, high

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and sinter now OFFERS YOU A CHOICE, for maximum productivity and
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Fig. 2 3D scan of MIM parts produced from the 63:37
http://www.cmfurnaces.com Tel: 973-338-6500 Fax: 973-338-1625
powder/binder mixture
Laboratory/
comprised 60 wt% palm stearin and 40wt% polyethylene.
.CO.UK
Production Z Blade
Mixers
Improved biocompatible HA/ The powder component was pre-mixed for 30 mins before Call for Papers issued for PM
Ti6Al4V implants by PIM adding and mixing in the binder. The powder loading for
the composite feedstock was reported to be 78.21 vol %.
Titanium 2015
r le
rude ailab The binder was removed through thermal debinding
t
Ex ns av Titanium alloy Ti6Al4V and hydroxyapatite (HA) are well The organisers of PM Titanium 2015, the Third
under argon flow with a slow heating rate employed in
to
i known materials used in implants with titanium showing Conference on Powder Processing, Consolidation and
op good mechanical properties and corrosion resistance and
the initial stage of debinding to remove the palm stearin Metallurgy of Titanium, have issued a Call for Papers.
and to avoid defects. The first stage used a 3C/min ramp The event will be held at the Leuphana University of
HA having excellent biocompatibility and bioactivity but
to 320C for 1h and the second stage a 5C/min ramp to Lneburg, Hamburg, Germany, from August 31 to
weak mechanical properties.
500C for 1h. Palm stearin and polyethylene decompose September 3, 2015. Abstracts are requested focusing on
Researchers at University Kebangsaan, Selangor,
at temperatures above 300 and 450C, respectively. The PM Titanium related topics such as:
Malaysia and Sriwijaya University, Indonesia, have been
debound parts were sintered under vacuum at 1100, 1200,
working on a research project to combine these two Powder production
and 1300C for 2 h. The rate of shrinkage for the sintered
materials to produce biocompatible composite implants Cost reduction
PIM composite at the different temperatures is shown in
by Powder Injection Moulding (PIM) using a mixture Microstructure
Fig. 1.
Mixing for Metal Injection Moulding? comprising 90 wt% Ti6Al4V 10wt% HA powder and a Additive Manufacturing
HA was found to decompose at sintering temperatures
palm stearin and polyethylene binder system for the PIM PM Ti alloys including TiAl
Winkworth Z (Sigma) blade and ZX (Sigma Extruder) to form a secondary phase which tends to cover the Ti
mixers used by MIM stock producers worldwide. feedstock. Metal Injection Moulding
alloy particles. The rate of decomposition of HA increased
Easy Clean chamber and blade removal versions available, Amir Arifin and his colleagues stated in their paper Pressing, HIP
with increasing sintering temperatures and decomposi-
avoiding batch to batch contamination. Powder Injection Molding of HA/Ti6Al4V composite using PM biomaterials
Vacuum, cored blades, oil / electric jacket, chamber sizes
tion left pores on the sintered parts with the HA behaving
palm stearin as binder for implant material (Materials
and controls options. as a space holder. The HA/Ti6Al4V sintered composite The conference will be co-chaired by Dr Thomas
and Design, Vol. 65, 01/2015, pp 1028-1034) that they used
Robust, reliable, minimal maintenance for high performance structure is reported to be fully supported by the titanium Ebel and Prof Florian Pyczak of Helmholtz-Zentrum
palm stearin as a binder component because as a natural
and reliability. alloy through the necking formation of the Ti particles. Geesthacht, Germany. The schedule will include the
material it is environmentally friendly and additionally it
For more information about Winkworth Mixers Fig. 2 shows the surface morphology of the sintered opportunity to visit neighbouring institutes and companies
has good properties both as lubricant and surfactant as
HA/Ti6Al4V PIM composite at the different sintering working in the field of titanium PM. The deadline for
Call Sales on: +44 (0)1256 305600 well as providing capillary pores to remove the backbone
temperatures. abstract submission is 30 April 2015.
E: info@mixer.co.uk binder during thermal debinding.
Flexural strength and Youngs modulus are two of the www.hzg.de/pmti2015
W: www.mixer.co.uk The researchers reported that a significant challenge
key strength criteria for human bone implants. Youngs
when combining two powders with different properties,
modulus for natural bone should range from 10 GPa to
such as powder size, type of powder (metal or ceramic),
30GPa depending on the location of the bone. A maximum
were the differences in the thermal expansion coefficient
flexural strength of 11.98 MPa and maximum Youngs
during sintering. For the Ti6Al4V alloy a mean particle
modulus of 44.26 GPa were achieved for the PIM HA/
size of 19.6 m was used and for the non-calcined HA the
Ti6Al4V composite at the sintering temperature of 1300C.
average particle size was 5 m. The powder composition
The researchers used in vitro testing to analyse the
was 90wt% Ti6Al4V + 10 wt% HA and the binder system
biocompatibility of the sintered PIM HA/Ti6Al4V compos-
ites by immersing the sintered parts in simulated body
fluid (SBF) solution for one, two, six and eight weeks
PolyMIM GmbH is a manufacturer offering two different
binder systems for MIM: with the weight of parts checked at each time point. It
was found that the weight changes of parts sintered
polyPOM our catalytic binder system at 1100C and 1200C is greater than parts sintered at
polyMIM our water soluble binder system 1300C at which the decomposition rate of HA increases.
These two binder systems have excellent characteristics
The weight loss of the samples in the early stages (first
during the production process and combine attractive week) is attributed to the dissolution of calcium ions from
prices with worldwide availability. the secondary HA phase after sintering. The samples
lost weight significantly after this period due to the start
Our portfolio covers high-end applications with our special of the Ca-P precipitation on the Ti particle surfaces. The
alloys as well as the mass production requirements seen Fig.1 Effect of sintering temperature on the shrinkage of
Ca-P precipitation process starts with the formation of
in the automotive and telecommunications industry, for HA/Ti6Al4V composite
example. calcium titanate on the surface of the Ti particles and this
continues with the formation of calcium and phosphate on
Every possible challenge in the MIM process can be the calcium titanate, which facilitates the formation of an
overcome with our range of products tailored to our amorphous calcium-phosphate layer.
customers requirements. Contact us to find a match for
After three weeks the Ti alloy particles enlarged
your application!
because of growth of the Ca-P phase, and after six to
Phone: +49 6751 85769-0 Fax: +49 6751 85769-5300 eight weeks the morphology of the sintered parts showed
Email: info@polymim.com a Ca-P layer with plate like crystals which increases the
bioactivity and biocompatibility of the PIM HA-Ti6Al4V
www.polymim.com Fig. 2 Surface morphology of sintered parts at various
composite.
sintering temperatures at (a, left) 1100C, (b, centre)
www.ukm.my
1200C, and (c, right) 1300C with 2 h holding time
| contents page | news | events | advertisers index | | contents page | news | events | advertisers index | Carbon control in MIM
Carbon Control:
An important discriminant in
Metal Injection Moulding
The challenge of carbon control has strongly influenced the development

of MIM technology, most obviously in relation to early material selections.
Appropriate carbon control is, however, no less important today and it is
recognised as one of the fundamental factors influencing final component
quality. Prof Randall German, San Diego State University, USA, reviews
the history of carbon control in MIM and considers the importance of
sintering atmospheres and binder systems, as well as reviewing the
relevant reactions that take place during the MIM processing cycle.
FCT Anlagenbau GmbH

promote, design, manufacture and sell systems for the development and production of
heavy-duty material. Two tests emerged in the evolution debinding, and silver was used to Carbonyl iron production arose
of Powder Injection Moulding identify the component after sintering. prior to MIM so various grades were
(PIM) to assess the sophistica- Ray Wiech came up with this colour already available when MIM trials
tion of component production scheme for his early technology began. These included grades for food
operations dimensional control variant as applied to carbonyl iron additives and grades for electrical,
Our performance The furnace specialist for and carbon control. With respect powder. The availability of this 5m magnetic and radar applications.
to dimensional control, Ceramic powder was critical to early commer- Powder impurity contamination levels
Consulting during the conception of a plant Vacuum Gas pressure sintering Injection Moulded (CIM) casting cores cial demonstrations, as other fine can range up to 2 wt %, depending
set the benchmark by holding 0.02% metal powders were scarce. on the post-synthesis treatment.
Development and design of plants Hot pressing Debinding
variation. Carbon control was more of
Manufacturing of plants Annealing Tempering a problem for metals, since ceramics
are often fired in air. For metals,
Start-up and After-Sales Service Sintering Heat treating carbon control challenges often led to
Maintenance and modernisation of existing plants a focus on zero carbon alloys. Today,
tiers of carbon level depend on the
final product, from less than 300 ppm
for austenitic stainless steels to more
than 5-6% for cemented carbides. In Weight
Applications between are a variety of steels and
tool steels with target carbon levels
change,
%
Maximum temperature continuous furnaces Sintering furnaces from 0.4 to 2%. Strategies for carbon
control require attention to powders,
Gas pressure sintering furnaces Vacuum hot presses binders and processing atmospheres.
Debinding and pyrolysis furnaces Thermal post combustion
Carbonyl iron powder
Special plants and manipulating eqiupments Solvent debinding system Temperature, C
Early in Metal Injection Moulding
(MIM) the term green identified the Fig. 1 Thermogravimetric data for the weight change of carbonyl iron powder
component after moulding, brown during heating in hydrogen, plotting the total weight loss and the specific
described the component after change in carbon, oxygen, and nitrogen content versus peak temperature
FCT Anlagenbau GmbH

Hnbacher Str. 10 Tel. +49 3675 / 7484-0 email: info@fct-anlagenbau.de
D-96515 Sonneberg Fax +49 3675 / 7484-44 web: www.fct-anlagenbau.com
Carbon control in MIM | contents page | news | events | advertisers index | | contents page | news | events | advertisers index | Carbon control in MIM
practice in MIM relied on an Background control. Dimensional control in dimensional and carbon control.
oxidising air atmosphere to slowly MIM, measured by coefficient of For success in solvent debinding, a
decompose the binder in an early A literature search on carbon variation as the standard deviation waxy phase is extracted in solvent
variant of thermal debinding. At the control in Metal Injection Moulding over the mean size, is generally (today polyethylene glycol in water
start, while the binder was present, uncovers abundant prior work. quoted at 0.2%. Unfortunately, audits is common) and a second stronger,
total carbon levels in the green part By the end of 2014 more than 230 sometimes find MIM production is insoluble polymer is added as the
measured 8wt%. Bringing that archival publications were available. more like 0.5% variation. Carbon backbone. The backbone polymer
down to say 0.6 or 0.4 wt. % to form Recently the focus has shifted away control often results in an emphasis provides handling strength between
steel was a difficult task. Instead, from ferrous alloys to more reactive on low carbon alloys, an upper solvent immersion and sintering.
heating cycles of days were used to systems, such as titanium, niobium limit of say 300 ppm. However, high During the sintering cycle it is
replace the binder with iron oxide and molybdenum. Formerly mainstay carbon compositions such as silicon removed by thermal pyrolysis. By
bonds between the particles. The efforts were on carbon control in carbide (SiC) and cemented carbide avoiding the intensive oxidation,
result was a brown or rust coloured cemented carbides, tungsten alloys, (WC-Co) reached production by the and associated decarburisation,
component with good handling aluminides, tool steels, stainless middle 1980s. Missing were the alloys sintered carbonyl iron products with
strength. Sintering under reducing steels, and low alloy steels. Most of and dimensional characteristics controlled carbon levels arose. Fig.2
conditions reversed that oxidation the issues associated with ferrous demanded by the firearm, industrial shows an example of the pearlite
to produce the smaller sized silver alloys were resolved during the 1990s and automotive industries. Heat microstructure achieved after
coloured component. as MIM underwent rapid commercial treatable steels by MIM emerged as sintering at 1300C. It has a final
The merit of relying on oxidation growth. The attached references new powders, binders, debinding and carbon level almost ideally at the
followed by reduction was evident intentionally cite important sintering notions focused on means eutectoid composition of 0.77 wt %.
in excellent magnetic properties contributions ranging from early to avoid total decarburisation during The shift to solvent debinding
Fig. 2 This optical micrograph shows the nearly perfect pearlitic microstructure leading to early MIM success in foundation work (Darken and Gurry) processing. enables the manipulation of final
from a carbonyl iron with 0.77 wt % retained carbon. The injection moulded electro-magnetic impact and to a recent survey (Hryha et al.). Probably the most significant carbon levels. Likewise, catalytic
material relied on a simple paraffin wax polyethylene binder, solvent matrix-dot printer applications. The As mentioned earlier, two advance came with the move debinding offers the same latitude.
debinding, and hydrogen sintering at 1300C chemical reactions during thermal metrics are discussed with regard to to solvent debinding. It is faster Now the starting carbon composition
debinding converted carbon into assessing different MIM technologies compared to oxidative thermal is adjusted to compensate for
Common impurities included As determined using gas volatile carbon monoxide or carbon dimensional control and carbon debinding and it provides better decarburisation during sintering,
nitrogen, hydrogen, oxygen, carbon chromatography the exact dioxide, with parallel formation
and silica; carbon and oxygen from species liberated depends on the of iron oxides. Handling strength
the carbon monoxide reaction atmosphere. Heating carbonyl iron arose from the cementing action of
used to form iron pentacarbonyl, powder in hydrogen is dominated by the oxide replacing binder between
hydrogen and nitrogen from the the production of water near 350C particles. Merits of this approach
ammonia decomposition catalyst followed by methane production near included desirable handling
and silica from deagglomeration 425C. Heating carbonyl iron powder strength and subsequently good
milling. Chemical reactions during in nitrogen, without the addition of sintering in a reducing atmosphere,
but zero carbon. Unfortunately
the air-based thermal debinding
The merit of relying on oxidation cycle required very slow heating
and lasted up to five days. The
followed by reduction was evident in time lapse from moulding to final
excellent magnetic properties leading product assessment (size, density,

composition) was a barrier since
to early MIM success in electro- manufacturing was moving to the
new just-in-time philosophy.
magnetic impact and matrix-dot For carbonyl iron components, if
printer applications. residual carbon is required, such as

in heat treatable steel, then carbides
were added to retain carbon. For
heating produced volatile products hydrogen, results in mostly carbon example, at low temperatures
as plotted in Fig.1. These data monoxide with peak formation near cementite (Fe3C) resists releasing
trace weight loss, as well as carbon, 550C. A mixture of nitrogen with carbon, but readily dissolves into
oxygen, and nitrogen contents, hydrogen gives a blend of these austenite at temperatures over
versus peak temperature during results. 727C during sintering. Indeed
heating in hydrogen. The total weight Reduced carbonyl grades are of most tool steels inherently rely on
loss during heating is often 2 wt % higher purity, but more expensive. this mechanism where refractory
through the formation of carbon Graphite additions provide a means carbides retain carbon to the
monoxide, carbon dioxide, steam, to add carbon and produce sintered sintering temperature.
and methane. steel. However, early binder removal
Cremer_1213_Anzeige_210x148_Gelb_V2
Mittwoch, 22. Januar 2014 14:32:56
mostly traced to oxygen in the powder. and 600-series (17-4 PH, 15-5 PH) oxidisation (from carbon dioxide or Hydrogen
Experiments determined each weight stainless steels, copper, nickel, oxygen), reduction (from hydrogen or Pure hydrogen as a sintering
percent of oxygen in the powder tungsten (W-Ni-Fe, W-Ni-Cu, W-Cu, carbon monoxide), nitridation (from atmosphere is superb for most
produced almost the same weight and W-Cu-Co), Invar, and Kovar. Early nitrogen or ammonia), carburisa- ferrous alloys, but is an expensive
percent carbon loss; the carbon feedstock brochures showed twenty tion (usually from methane), and option. Liquid hydrogen is pure and
formed roughly equal parts CO and or more alloys, but noteworthy was decarburisation (from carbon dioxide helps generate atmospheres with
CO2. For example, to obtain 0.6 wt% the absence of carbon containing or steam). Combinations such as less than 1 ppm oxygen and 8 ppm
final carbon using a powder with steels. hydrogen doped with methane water. At the sintering temperature
oxygen
0.2wt % oxygen required admixture enable carburisation and reduction hydrogen is slightly soluble in most partial
of 0.2 wt % sacrificial graphite plus Atmosphere basics at the same time. When sintering ferrous alloys. Further, stainless pressure
the desired 0.6 wt % final carbon or a ferrous MIM components the typical steels have from 12 to 20 wt. %
starting level of 0.8 wt %. Difficulties To understand final carbon levels in atmosphere choices are vacuum, chromium and hydrogen reduces the
arose when the starting powders MIM requires consideration of the hydrogen, and nitrogen-hydrogen. normal chromium oxide film on the
varied in carbon to oxygen ratio, starting powder, sintering furnace Other combinations are in use, for particle surface.
requiring adjustments in added operation, binder composition, and example argon-hydrogen, but since Another benefit from sintering in
graphite. One company used blends sintering atmosphere. The sintering argon is inert it only acts to fill pores hydrogen is the improved corrosion
of different oxygen content powders, atmosphere is important since it and retard sintering densification. For resistance. Hydrogen suppresses Temperature, C
gas versus water atomised, to control performs several roles, the most high density MIM components, the chromium evaporation at the
input oxygen and carbon. critical being to protect the compact atmosphere must be soluble in the sintering temperature. Chromium Fig. 3 The separation between iron and iron oxide is plotted as the oxygen
Until these results were known, from oxidation at high temperatures. metal at the sintering temperature. has a higher vapour pressure versus partial pressure versus temperature, with oxidising conditions above the line
most early MIM fabricators elected Further, the atmosphere removes Then as pores close, like a helium nickel and iron and evaporates when and reducing conditions below the line. Vacuum sintering at temperatures over
to avoid carbon control issues and burnout products by sweeping away balloon, the pores lose gas pressure, sintering in vacuum. Consequently it 1200C typically occurs under reducing conditions
focused on applications where the reaction products. Manipulations shrink, and annihilate. Sintering in is partially depleted on the component
carbon was stripped from the alloy. of carbon during sintering are inert argon is not able to remove the surface, just the opposite of what
Accordingly, early MIM offerings were possible via atmosphere control. argon and impedes final densification. is needed for corrosion resistance. atmosphere reach tensile strengths environment, neither carburising
mostly low carbon variants Fe-2Ni, Reactions involving the atmos- High densities are possible, but not Hydrogen reduces surface oxides, of 3000 MPa with 3% elongation. nor decarburising. Most steels
Fe-8Ni, 300-series (304L and 316L) phere during sintering include full density. enabling strong metallurgical bonds Sintering atmospheres based on easily sinter in vacuum and it is very
between particles, but suppresses the nitrogen are doped with controlled successful for sintering tool steels.
evaporation kinetics giving improved levels of methane or hydrogen,
chromium retention. commonly with 80 and 97% nitrogen.
Binders
On exposure to air, chromium A high nitrogen level lowers cost
reforms the surface oxide. Although and flammability. Since 80% of all In heating a MIM component to
the oxide is too thin to see, being air is nitrogen, inexpensive on-site sintering temperature it is important
transparent to light, its tenacious generators provide essentially to extract the last backbone polymer
SINTERING FURNACES character is sufficient to prevent unlimited nitrogen supplies via without leaving residual carbon.
corrosion. However, the oxide on the cryogenic or molecular sieve This is a failing in several of the
starting powder makes sintering techniques. newly promoted binder formulations,
difficult. Instead of sintering stainless namely the backbone polymer
steel, chromium oxide Cr2O3 requires Vacuum is too difficult to extract without
a sintering temperature above the Vacuum sintering implies a reduced shifting the final carbon level. If the
melting point of stainless steel. pressure, but it is not devoid of backbone polymer is heated to high
6 0 b a r S i n t e r - HIP Sy s t e m Sintering requires reduction of the atmosphere. The pressure in temperatures without evaporation,
oxide, meaning reacting hydrogen the sintering chamber is one then decomposition into graphite
with the oxide to form water vapour. ten-thousandth to one millionth of results in a higher carbon level. In
That water vapour reaction product atmospheric pressure. As plotted in this regard, linear molecules are
is swept away in the furnace. Pure Fig. 3, a low oxygen partial pressure fairly easy to extract, but polymers
hydrogen is the preferred sintering is reducing for iron at typical sintering such as agar, cellulose, polystyrene
atmosphere for stainless steels, temperatures. Reduction occurs in or other aromatic polymers increase
in spite of concerns over reactivity, an all-metal furnace with a diffusion carbon content. Strategies with these
flammability and cost. pumped vacuum. Many vacuum binders rely on exposure to oxidising
furnaces employ graphite heaters. conditions during heating for alloys
Nitrogen In those cases residual oxygen where the oxides can be subsequently
M I M Sy s t e m Nitrogen is neutral or even beneficial
for most ferrous alloys. In steel it is
from the MIM component reacts
with carbon to form low pressure
reduced in sintering. This is not
workable with titanium and other
an interstitial the same as carbon, carbon monoxide as the reducing reactive metals.
increasing strength. Indeed, MIM atmosphere. Under controlled Most polymers decompose by
steels sintered with carbide additions conditions, vacuum sintering provides forming volatile molecules during
TAV SpA - Via dell'Industria, 11 - 24043 Caravaggio (BG) - ITALY - P +39 0363 3557 11 - www.tav-vacuumfurnaces.com and nitrogen as the sintering a clean, reproducible and nonreactive heating - methane, ethane, butane,
residual carbon from backbone with typical MIM binders find best
polymer decomposition. A flowing polymer extraction occurs in an
CO2 content, %
atmosphere sweeps away the burnout atmosphere consisting of hydrogen or Iron oxidation and reduction
products, preventing high temperature nitrogen and hydrogen. High hydrogen
carburisation reactions. Unfortunately, content enhances methane formation,
oxidation at high temperatures meaning less carbon residue from the
results in decarburisation. So the binder. Indeed, the optimal procedure
use of atmospheres with oxidants is is to use pure hydrogen or hydrogen
restricted to low temperatures. with water vapour below 200C with
When polymer burnout is acceler- a progressive shift to nearly pure
ated, sooting occurs and surfaces nitrogen at high temperatures. This
fo Oxygen fraction
become blemished. In a few cases, proves difficult to manage, so as a
defects form within the component. default essentially pure nitrogen is
Sooting occurs when the compacts are employed for the whole cycle.
Retained carbon, %
heated too rapidly, without sufficient The indications of improper
oxidant (water or oxygen). The polymer burnout are sooting, low strength, high
forms graphite smoke that falls on carbon level, blistering and property
the compacts. It is more of a problem or dimension variation with location in
Fig. 4 The carbon uptake from the sintering atmosphere as a function of the
with high loading in the furnace, high the furnace. For most cases the cure
carbon dioxide content for two temperatures. Note both axes are logarithmic
heating rate, low atmosphere flow is slower heating, more oxidant in the
rates and large components. atmosphere, and a faster atmosphere
propane, carbon monoxide, carbon to shift decomposition to even Best practice is to remove the flow over the components. Computer
dioxide and water. Decomposi- lower temperatures to avoid carbon backbone polymer by slow heating in simulations of furnace performance,
ff Carbon fraction
tion starts early in the heating contamination. The atmosphere role the early portion of the sintering cycle. including polymer burnout, help
cycle, peaking near 450C, and is in burnout comes from provision Atmosphere turnover is managed identify problems, but these seem to
completed by 550C. For reactive of species to facilitate polymer to remove the burnout products. have been lost to MIM in recent years. Fig. 5 The boundary between oxidation and reduction for iron shown for several
metals, such as titanium, intention- decomposition. For example, oxygen, This means gas flow is adjusted for Realistic solutions rely on closed- temperatures based on atmosphere carbon fraction and oxygen fraction. For
ally short molecules are required carbon dioxide, or water removes changes in furnace loading. Trials loop control systems that read the each temperature the line demarks the oxidation and reduction separation.
furnace situation and make constant Hydrogen, carbon monoxide and methane are reducing at all temperatures
adjustments to the composition and
atmosphere flow to improve burnout.
tions are oxidation-reduction and oxygen pressure and temperature to
carburisation-decarburisation. The show the transition between oxidation
www.eisenmann.com Critical metallurgical reactions involving iron (Fe) rely on (iron and oxygen going to iron oxide)
www.ruhstrat.com
reactions equilibrium between oxygen and the and reduction (iron oxide going to iron
oxide, such as FeO, and can be written and oxygen). At a typical sintering
Ferrous metallurgy mastered the as follows: temperature, reduction requires
next
critical reactions in conventional an atmosphere with less than 10-13
steelmaking long before MIM. Fe (s) + O2 (g) FeO (s) parts of oxygen to avoid oxidation,
The keys in MIM rely on control- which is achievable in most systems.
gener ation ling oxidation-reduction and
carburisation-decarburisation. This
The symbols are important and tell
that the iron (Fe) and iron oxide (FeO)
Alternatively, oxidation occurs when
the oxygen partial pressure in the
high temperature mastery is particularly necessary for are solids as indicated by the (s), and sintering atmosphere is above
roller furnaces MIM automotive component produc-

tion as heat treatments are used to
oxygen is a gas (g). This is a reversible
reaction that progresses either way as
the line. Note higher sintering
temperatures make reduction easier,
deliver the required hardness, wear indicated by the two-way arrow . A especially with hydrogen. Likewise,
resistance and strength. Even today, high concentration of oxygen leads to carbon in the compact or graphite
Custom designed thermal debinding equipment with all of the push for fuel economy iron oxide production. Alternatively, at furnace heaters tip a vacuum into
in automobiles, two-thirds of the high temperature a high concentration reduction conditions.
Continuous debinding and sintering furnaces for MIM typical vehicle is still steel. Only a tiny of iron oxide results in formation Iron oxide is reduced using
portion of that steel is produced by of oxygen and pure iron, as occurs hydrogen as follows:
MIM. Below are some of the critical
Modular roller hearth sintering furnaces in vacuum sintering. It is like a
metallurgical reactions that underpin playground seesaw, push down on FeO (s) + H2 (g) Fe (s) + H2O (g)
Powder reduction furnaces up to 2600 C carbon control. one side and the other side goes up
- increase the oxygen around iron and or alternatively for reduction of solid
A global service and manufacturing network Oxidation-reduction iron oxide production is favoured. Fe2O3 by gaseous hydrogen,
Thermochemical reactions are Earlier, Fig. 3 plotted the oxygen
fundamental to carbon control in partial pressure effect on oxidation- Fe2O3 (s) + 3 H2 (g) 2 Fe (s)
Pioneers for High Temperature Furnaces since 1896 MIM steels. The dominant reac- reduction. This plot balances the + 3 H2O (g)
reduction occurs during sintering more thermodynamically stable

Iron carburisation and decarburisation when the CO partial pressure exceeds carbides such as chromium carbide
the CO2 partial pressure. are contraindicated. With cementite
additions, carbon dissolves into iron in
Carburisation-decarburisation the 727 to 900C range.
Carbon is a potent and necessary Consider the reaction involving the
strengthening agent in steels. Precise carbide in steel with water vapour
control of the final carbon content (steam) during sintering,
mandates an understanding of
fo Oxygen fraction
carburisation and decarburisation Fe3C (s) + H2O (g) 3 Fe (s)

events. Because of the reactions + CO (g) + H2 (g)
between carbon, oxygen and
hydrogen, it is possible to add or An increase in water pressure is
subtract carbon from the compact one means to decarburise steel.
based on specific atmosphere Atmospheres with low water vapour
attributes. The important atmosphere levels (dry or low dew points) avoid
species are carbon monoxide, carbon removal during sintering.
methane, and carbon dioxide. Due to the possible generation of
Fig. 7. A cross-section through a sintered MIM firearm component that has
As a first example, the general methane, slow decarburisation is
decarburised on the outside surface due to improper atmosphere control
reaction between iron (Fe) and its possible during sintering in dry
ff Carbon fraction
carbide (Fe3C) is considered in terms hydrogen. However this is a slow
of the carbon monoxide (CO) or reaction that is often ignored. In the above reactions, FeO and carbon dissolved in steel participate
Fig. 6. A map of the carburisation and decarburisation regions for several
methane (CH4) reactions, Therefore, sintering in high purity Fe3C are used to illustrate the oxygen in these same reactions. At 1250C
temperatures and atmosphere compositions in terms of the oxygen fraction
hydrogen is a most desirable option and carbon roles in iron reactions the phase diagrams indicate the
and carbon fraction. Water and carbon dioxide always cause decarburisation,
3 Fe (s) + 2 CO (g) Fe3C (s) for retention of carbon in MIM steels; with the atmosphere. Actually, the solubility limit for oxygen in iron is
while methane always causes carburisation
+ CO2 (g) hydrogen gives both oxide reduction oxygen and carbon do not have to about 0.2 wt% and the solubility limit
and carbon retention. form compounds. Instead, oxygen and for carbon in iron is 1.5 wt %. At this
The partial pressure ratio of to 0.01 vol % water vapour and is 3 Fe (s) + CH4 (g) Fe3C (s)
hydrogen to water determines the reducing for most metals. Gold, + 2 H2 (g)
reaction progression. At a sintering silver, copper and nickel are easily
temperature near 1200C reduction reduced, while niobium, silicon, Although shown here as forming
is favoured by an atmosphere with titanium and vanadium oxides resist cementite Fe3C, at low concentrations
hydrogen to water pressure ratio reduction. Iron oxides are easily the carbon will be in solution. The
over unity. If iron (Fe) is heated in reduced compared to chromium relation between retained carbon and
the presence of steam (water vapour oxide Cr2O3. Thus, atmosphere carbon dioxide content is plotted in
or H2O), then iron oxide (FeO) and conditions that prove reducing for Fig.4 for two temperatures. Higher
hydrogen (H2) form. Alternatively, if iron can be oxidising to chromium. retained carbon levels mandate
iron oxide and hydrogen are heated For proper sintering, reducing all less carbon dioxide. Alternatively a
together, the reaction produces iron of the oxide is desirable prior to high carbon dioxide content drives
and water vapour. A constant supply reaching a high temperature. decarburisation via carbon monoxide
of fresh hydrogen is required for total The two reducing species effective generation. Sintering in a vacuum
oxide reduction, meaning the water in sintering ferrous alloys are carbon with graphite heaters leads to a
vapour product is constantly swept monoxide (CO) and hydrogen (H2). reaction between residual oxygen
away from the MIM component. The oxidation-reduction reaction and graphite to generate CO. Carbon
Note the water vapour and involving carbon monoxide is similar monoxide reduction of iron is most
hydrogen contents appear on opposite to that for hydrogen, evident at temperatures over about
sides of the reaction. This means the 800C. On the other hand, carbon-
direction of the reaction depends on FeO (s) + CO (g) Fe (s) + CO2 (g) based reduction of chromium oxide
the concentration ratio of water and does not occur until about 1250C.
hydrogen, a parameter measured by In this case the partial pressure ratio Graphite heating elements provide a
the dew point. The dew point tells the of carbon monoxide CO and carbon carburising environment useful for
temperature at which water vapour dioxide CO2 is important. A high sintering MIM tool steels.
will condense and is a measure of partial pressure of carbon dioxide Besides heating elements,
the moisture content in the sintering leads to iron oxidation (it pushes the carbon can be introduced from
atmosphere. A dew point of 7C reaction to the left) and a high partial the decomposed polymers or by
corresponds to 1 vol % water vapour pressure of carbon monoxide leads intentional graphite additions to the
and is oxidising for most metals, while to iron reduction, since it pushes the powder. The powder sources include
a dew point of -42C corresponds reaction to the right. Again, for iron graphite and cementite (Fe3C), but
temperature and concentration levels and atmosphere combinations. introduced as computer control enables MIM access to many high S Wiberg, and S Berg, Carbon P H Booker, J Gaspervich and R
the FeO or Fe3C compounds would The horizontal axis is the atomic systems for MIM in 1991, but the volume applications for automotive, Control in PM Sintering: Industrial M German (eds.), Metal Powder
dissolve into iron and only precipitate fraction of carbon (for example high equipment expense and poor hand tool, firearm and industrial Applications and Experience, Powder Industries Federation, Princeton, NJ,
on cooling. pure methane CH4 is 20% carbon demand for carbon control made components. Metallurgy, 2013, vol. 56, pp. 5-10. 1992, pp. 203-217.
since there are five atoms and one for poor acceptance. Today, with
S Igarashi, M Achikita, and S P Quadbeck, B Schreyer, A Strauss,
Controlling reactions is carbon), while the vertical axis is computer controls, production
Author Matsuda, Evolution of Gases and T Weissgarber, and B Kieback, In
the atomic fraction of oxygen (water furnace closed-loop feedback control
Sintering Behavior in Carbonyl Iron Situ Monitoring of Gas Atmospheres
We see that several reactions act H2O is 33% oxygen since one of the systems demonstrate carbon control Randall M. German Powder for Metal Injection Molding, During Debinding and Sintering of
to control carbon levels in MIM three atoms is oxygen). Note nitrogen of 0.05%. Professor of Mechanical Engineering Powder Injection Molding Symposium PM Components, Proceedings PM
steels. Consider the five main gas is not an actor and is ignored, and San Diego State University 1992, P H Booker, J Gaspervich and 2010 World Congress, Florence Italy
species identified here - CO, CO2, hydrogen is always reducing. For San Diego
Final considerations R M German (eds.), Metal Powder October 2010, European Powder
H2, H2O and CH4 (carbon monoxide, each temperature a line represents California, USA Industries Federation, Princeton, NJ, Metallurgy Association, Shrewsbury,
carbon dioxide, hydrogen, water the balance between oxidation and Several factors impact final carbon Email: rgerman@mail.sdsu.edu 1992, pp. 393-407. UK, on CD.
and methane). Two key atmosphere reduction. Reduction is achieved level. Two that dominate MIM are
reactions are as follows: by processing in an atmosphere the starting powder composition, M Kearns, K Murray, and T Tingskog, E Streicher and R M German, Process
located below the equilibrium namely the oxygen content and Important literature Effects of Particle Size and Alloy for Controlling Carbon Content of
CO2 (g) + H2 (g) CO (g) + H2O (g) line, corresponding to low oxygen carbon content. Added iron carbide Chemistry on Processing and Injection Molding Steels During
and contents. or graphite powders are a means to E C Bain and H W Paxton, Alloying Properties of MIM Powders, Advances Debinding, U. S. Patent 5,334,341,
CH4 (g) + H2O (g) CO (g) + 3 H2 (g) Fig. 6 uses the same plotting offset carbon loss due to oxygen in Elements in Steel, American Society in Powder Metallurgy and Particulate issued 2 August 1994.
scheme, but now shows the the powder. The atmosphere used for Metals, Metals Park, OH, 1966. Materials - 2009, Metal Powder
M W Wu, K S Hwang, and K H
Full control of the carbon reactions temperature profiles for carburisation for heating is the other dominant Industries Federation, Princeton, NJ,
D R Bankovic and R M German, Chuang, Improved Distribution of
revolves around measuring and and decarburisation. Again factor. Based on oxidation-reduction 2009, pp. 4.1-4.8.
Optimization of Debinding Cycles in Nickel and Carbon in Sintered Steels
adjusting these species. Quantitative nitrogen is absent as it is a neutral and carburisation-decarburisation Powder Injection Molding, Advances S Krug and S Zachmann, Influence through Addition of Chromium and
measure of the carbon potential is atmosphere. Hydrogen is slightly maps, it is possible to tailor the in Powder Metallurgy, vol. 3, Metal of Sintering Conditions and Furnace Molybdenum, Powder Metallurgy,
determined by the ratio of these two decarburising at low temperatures, atmosphere composition for the Powder Industries Federation, Technology on Chemical and 2008, vol. 51, pp. 160-165.
gases. but the kinetics are slow, and at desired final composition usually Princeton, NJ, 1990, pp. 223-232. Mechanical Properties of Injection
During sintering MIM steels, high temperatures it is neutral with reduced with little carbon change. In Moulded 316L, Powder Injection
respect to carbon. Wet hydrogen is that regard three atmospheres are L S Darken and R N Gurry, Physical
if oxygen is present, then either Moulding International, 2009, vol. 3,
decarburising. Further, the conditions most successful for MIM; hydrogen, Chemistry of Metals, McGraw-Hill,
the compact or the atmosphere no. 4, pp. 66-71.
change with temperature, leading nitrogen-hydrogen and vacuum. New York, NY, 1953.
is doped with carbon (graphite
Any other combination faces V M Kryachek, Injection Moulding
or methane) to compensate for to problems such as evident in Fig. J Ebenhoech and H Wohlfromm,
difficulty. Sensors coupled (Review), Powder Metallurgy and
decarburisation. To obtain target 7. This micrograph is from a MIM Control of Composition and
with computer controls enable Metal Ceramics, 2004, vol. 43, pp.
sintered properties requires oxide firearm component that decarburised Microstructure of Injection Molded
adjustments to the process 336-348.
reduction while controlling final near the surface, most probably Steel Parts Using Elemental
atmosphere targeted around final Powders, Advances in Powder C Lall, Principles and Applications of
carbon levels. For low final carbon Metallurgy and Particulate Materials High Temperature Sintering, Reviews
With analytical sensors on the levels, case carburisation is an easier
means to satisfy the performance
- 1995, Metal Powder Industries in Particulate Materials, 1993, vol. 1,
pp. 75-107.
Federation, Princeton, NJ, 1995, pp.
furnace and atmosphere control goals. For intermediate carbon levels 6.95-6.102. B Levenfeld, A Varez, and J M
it is appropriate to constantly monitor
algorithms, precise carbon control and control atmosphere quality.
R Fagan (ed.), Vacuum Technology, Torralba, A Modified Injection
Process of Metal Powders Using a
Practical Heat Treating and Brazing,
enables MIM access to many high Finally, for high carbon levels the
carbon should be tied up in a stable
ASM International, Materials Park, Thermosetting Binder, Proceedings
volume applications for automotive, carbide (SiC, WC, TiC, Cr2C3 and such)
OH, 1993. of the 2000 Powder Metallurgy World
Congress, Part 1, K Kosuge and H
where it resists decarburisation. R M German, Sintering Theory and
hand tool, firearm and industrial The several reactions and species Practice, Wiley, New York, NY, 1996.
Nagai (eds.), Japan Society of Powder
and Powder Metallurgy, Kyoto, Japan,
components. (CO, CO2, H2, H2O and CH4) actually
involve just three elements (carbon,
R M German and A Bose, Injection 2000, pp. 274-277.
Molding of Metals and Ceramics,
hydrogen, and oxygen) and two H Miura and T Honda, Establishment
Metal Powder Industries Federation,
carbon level. An important map for due to moisture in the process independent gaseous reactions. of Metal Injection Molding (MIM)
Princeton, NJ, 1997.
iron and steels relies on the atomic atmosphere. Ultimately MIM component carbon Process and Its Application, Journal
fraction of oxygen (fO = atoms of Instrumentation allows control traces to monitoring Y L Ho and S T Lin, Debinding of the Japan Society of Powder and
oxygen divided by total atoms in measurement of the atmosphere and control of a few atmosphere Variables Affecting the Residual Powder Metallurgy, 1996, vol. 43, pp.
atmosphere) and carbon (fC = atoms quality and from the basic relations constituents, as well as the starting Carbon Content of Injection Molded 829-839.
of carbon divided by total atoms in controls are enabled to adjust furnace powder carbon and oxygen levels. Fe-2 pct. Ni Steels, Metallurgical and
H Miura, T Honda, K F Hens, and R
atmosphere) showing the balance conditions where oxides are reduced With analytical sensors on the Materials Transactions, 1995, vol.
M German, High Performance 4600
between oxidation and reduction. Fig. while avoiding decarburisation or furnace and atmosphere control 26A, pp. 133-142.
Steels by Injection Molding, Powder
5 is a map for several temperatures carburisation. These ideas were algorithms, precise carbon control E Hryha, L Nyborg, A Malas, Injection Molding Symposium 1992,
| contents page | news | events | advertisers index | | contents page | news | events | advertisers index | MIM at GKN Sinter Metals
MIM at GKN Sinter Metals:

Process automation enables
growth in automotive
applications
It has been eight years since PIM International last visited GKN Sinter Metals
Bad Langensalza Metal Injection Moulding (MIM) plant, one of Europes
largest MIM operations. Much has happened in the intervening period, with
awareness of the technology improving and global MIM sales jumping from
around $950 million in 2007 to an estimated $1.5 billion in 2014. Dr Georg
Schlieper reports on the development of MIM in Bad Langensalza and the
opportunities that lie ahead.
According to its own statements GKN A history of the Bad province of Thuringia. Nearby is the
Sinter Metals is the worlds leading Hainich National Park, a UNESCO
Langensalza plant
supplier of Powder Metallurgy (PM) World Natural Heritage site that
based precision components, with GKN Sinter Metals plant in Bad includes 13,000 hectares of deciduous
more than thirty facilities on five Langensalza has been witness to a woodland.
continents. The group employs more turbulent period in history, from its Founded in 1967, the first factory
than 6500 people worldwide and has foundation behind the iron curtain was originally a training centre for
production sites in Germany, Italy, in the former German Democratic toolmakers, draughtsmen, metal
South Africa, India, China, Brazil, Republic (GDR) to its present role workers and electricians associated
Argentina, Canada and the USA. as a global supplier based in a with the Robotron Combine in the
GKN Sinter Metals GmbH in Bad reunified Germany. Bad Langensalza provincial capital of Erfurt, a centre
Langensalza, Germany, is the only itself is an attractive spa town in the for the manufacture of electrical
plant in the group that produces Metal
Injection Moulded (MIM) parts.
Since the earliest days of its MIM
activities GKN Sinter Metals took
full advantage of its close relation-
ship with the automotive industry,
a relationship which had been
established through its conventional
press and sinter PM parts busi-
ness. It was therefore an obvious
management decision that GKNs
sales engineers should pool their
capabilities regarding certain groups
of automotive products, particularly
where the company had acquired
unique technological knowledge.
Consequently, todays portfolio of
MIM products at GKN has a strong
emphasis on automotive applications. Fig. 1 The GKN Sinter Metals MIM plant in Bad Langensalza
MIM at GKN Sinter Metals | contents page | news | events | advertisers index | | contents page | news | events | advertisers index | MIM at GKN Sinter Metals
moulding of thermosetting plastics MIM technology in Bad

was transferred to Bad Langensalza.
Langensalza
When in 1996 a suitable plant was
needed for the new Metal Injection GKN began its MIM production with
Moulding facility, the choice of Bad BASFs Catamold feedstock system.
Langensalza was obvious because it This polyacetal-based system is
was the only plant in the group with still the standard feedstock used
experience in injection moulding, in the plant as GKN appreciates
whereas the other Krebsge its excellent process stability and
plants produced press and sinter shape repeatability. Daniel Bader,
components. The MIM process was Plant Manager at Bad Langensalza
relatively new in Europe and the Bad since October 2013, stated, Many
Langensalza plant was one of the of our customers in the automotive
pioneers of the commercialisation of industry are reluctant to change from
MIM technology in Europe. reliable processes because there is
In 1997 the plants ownership always a risk of failure associated
changed again when the Krebsge with innovation. Jack Schwarz, R&D
Group was acquired and integrated Manager, added, We appreciate the
Fig. 2 MIM products manufactured by GKN Sinter Metals include numerous into the GKN Sinter Metals Group, catalytic debinding system because Fig. 4 Computer image of a switchable roller finger follower
automotive parts such as turbocharger components, lock caps and more part of the UKs GKN plc. The it provides the best process stability
plant has since operated under the and this is the reason why we are so
name GKN Sinter Metals GmbH, successful in the automotive industry.
Bad Langensalza. The quality of For automotive customers reliable
MIM products steadily improved supplies over many years are more
with experience and technological important than the lowest possible
advances and in 2000 the first quality prices.
assurance certification, QS 9000, was It is widely known in the MIM
obtained. This was soon followed with industry, however, that parts
ISO 14001 and TS 16949. requiring a long fill path through
MIM production grew steadily and narrow cross-sections are difficult
in 2001 the press and sinter operation and sometimes impossible to mould
at Bad Langensalza was transferred with this type of feedstock. For these
to GKNs plant in Bruneck, Italy, in types of parts GKN has developed a
order to create more space for the proprietary binder system based on
flourishing MIM operation. In 2003 solvent debinding technology and a
the capacity of the original premises feedstock compounding line has been
in the city centre was fully stretched established.
and further growth was impossible in
the existing building. A modern new Automation Fig. 5 Four consecutive stages of a computer simulated mould fill study for the
factory with a floor space of 4300m The automation of injection moulding Switchable roller finger follower, shown above
Fig. 3 MIM-Master sintering furnaces at Bad Langensalza
was therefore constructed on a machines is being continuously
business park on the outskirts of the enhanced at GKN. For high volume
appliances. The majority of the 240 and office machines. town (Fig. 1). Besides MIM there is parts the company operates fully machining operation carry the risk of Secondary operations
trainees who left the training centre When the iron curtain fell and still a small business unit in operation integrated automatic standalone inducing defects in green parts. Secondary operations such as sizing,
each year started their careers in the the communist economic system for thermoset plastic parts. moulding units where feedstock is fed coining or grinding may be applied
Robotron Optima Combine producing collapsed in 1989, a period of Between 2003 and 2008 the in on one side and trays with green Debinding and sintering in order to meet particularly close
office machinery. In 1973 the plant uncertainty followed until Krebsge business grew rapidly until the global parts leave on the other side ready for Debinding and sintering is carried out dimensional tolerances. The whole
began to produce tooling for internal Sinterholding took over the PM plant financial crisis abruptly stopped the debinding. The moulding units include in continuous Cremer MIM-Master plant is organised with a view to
use in the Robotron Group. in 1992 and provided technical and upsurge. The period of economic a feed pipe that conveys the feedstock furnaces designed according to the efficiently and a number of secondary
Powder Metallurgy production financial support for the transforma- downturn, resulting in a slump in from its bin to the hopper of the injec- walking-beam principle (Fig.3). The operations are carried out in-house.
began in 1982 with the manufacture tion required to survive in the Western car sales worldwide, was used to tion moulding machine. Green parts green parts are placed in boats that Machining operations as well as heat
of press and sinter PM parts for free market economy. Under the streamline internal procedures and are then removed from the mould are then transported through the treatment and surface treatment
electric typewriters by the split name Metallwerk Langensalza invest in process automation. Today by a robotic arm, stripped from the furnace with a so-called walking- are usually outsourced. Decisions
die compaction (Olivetti) process, GmbH the plant became part of the GKN Sinter Metals GmbH in Bad runners and placed on tablets. The beam mechanism. This allows the about outsourcing or in-house
under licence from West Germanys Krebsge Group. Machine operators Langensalza is among Europes top runners are immediately re-ground movement of parts through the manufacturing are made on a case by
Krebsge Sinterholding. Until 1989 were trained in injection moulding three MIM parts manufacturers. A and added to the fresh feedstock. furnace with a minimum of vibration. case basis, depending on the product
the plant produced PM parts primarily technology at one of the Krebsge selection of MIM products manufac- Green part machining is avoided The sintering furnaces are operated requirements and an economic
for Robotron and Olivetti typewriters Groups other plants and the injection tured by GKN is shown in Fig. 2. because the mechanical stresses of a 24 hours a day, seven days a week. efficiency analysis.
MIM at GKN Sinter Metals | contents page | news | events | advertisers index | | contents page | news | events | advertisers index | MIM at GKN Sinter Metals
materials accounting for similar

volumes of production. In addition,
high temperature materials are
processed for turbocharger applica-
tions. Soft magnetic materials are
also available. Limited production
volumes, however, currently make
this material less attractive to a
high volume producer such as GKN.
Although the focus at GKN is on mass
production, smaller volumes are
produced so long as the cost of the
tooling can be accommodated.
Production volumes for automo-
tive parts range from 100,000 to
several million parts per year. The
cost-effective production of these high
volumes requires a high degree of
Fig. 6 MIM bicycle transmission component and axis with the same part (inset) Fig. 7 GKN Sinter Metals MIM parts for Otto Bocks prosthetic knee joint
process automation. Consequently,
(blocking plate, blocking hook and twin connecting plate)
GKN has invested in process automa-
The plant has around 100 the number of gates. All this has green parts has a high priority since tion and quality assurance equipment.
employees working in three shifts, brought significant improvements in defective parts that are detected
five days a week. The groups own the quality of the tooling as well as immediately after injection moulding Computer simulation aids the
resources are widely used for the reducing lead times. Both cold and can be recycled and need not go development of complex automotive
training of its personnel. Since MIM hot runner systems are used. through the complete debinding and components
is a specialist technology requiring sintering process, saving both raw The roller finger follower shown in
expert knowledge that is not avail- Quality Management materials and energy. Fig. 4 is an excellent example of how
able in the local area, machine and Quality assurance is of the highest MIM design can integrate a variety
furnace operators are trained within importance at GKN, with some of functions in a single component.
MIM in the automotive
the group. Workers with experience of components subject to 100% fully The part is used in the valve train
injection moulding from the plastics automatic non-destructive testing
industry of passenger cars as part of a cam
industry are trained in-house in the for cracks using acoustic resonance A large number of automotive MIM follower system that is capable of
special requirements of MIM. Five technology. New parts are also applications are found in car engines shutting off a cylinder while the
apprenticeships are currently in regularly checked for internal cracks and transmissions. These include engine is running. Due to the high
progress. by Computer Tomography (CT). Bader parts of the fuel injection system, strength of the heat treated steel a
stated, As a supplier to the automo- valve train system, turbochargers and lightweight design could be achieved.
Tooling design tive industry we are committed to sensor housings used in aggressive The computer simulation of mould
MIM tool design is undertaken maintaining a computerised quality environments including exhaust gas filling was performed during the
in-house using FEM software and all management system. applications where there are high development of the tooling. In this
Fig. 8 An Otto Bock stretching unit with twin connecting plate
tools undergo a mould fill simulation GKN operates a worker self- temperatures and pressures. process the flow of the feedstock into
Valve train and powertrain compo- the mould cavities is simulated and
nents primarily require high strength at the same time the temperature
Quality assurance is of the and wear resistance. Materials used distribution within the mould cavity
new market for MIM components.
This type of application requires
GKN already enjoyed a strong position
as a supplier of conventional press
highest importance at GKN, with are typically low alloy steels and
the parts are case hardened. Bader
is observed, as can be seen in Fig. 5.
Areas where the flow is divided and
high precision and strength in
combination with complex shapes
and sinter PM parts to Otto Bock.
MIM technology was introduced at
some components subject to 100% stated, We see a trend towards more where sectional flows merge again and small sizes. MIM is therefore a a technology day in 2009 at Otto
complex part design in the automotive can be studied and different gate
fully automatic non-destructive industry, integrating more functions options can be tested at an early
natural fit, enabling the processing
of large volumes of parts at relatively
Bocks R&D Centre and as a result a
number of new designs of prosthesis
testing for cracks using acoustic into a component, and these complex
parts can best be produced in large
stage before the decision about the
final mould design is made.
low costs. Fig.6 shows a bicycle
transmission component produced by
components were developed based on
the design guidelines for MIM (Figs.7
resonance technology volumes by Metal Injection Moulding. MIM. Other non-automotive applica- and 8).
Our technology also excels over Non-automotive MIM tions include sensor housings for food Medical technology requires
Investment Casting thanks to higher processing and process automation. complexity, corrosion resistance and
applications at GKN
test. These tests demonstrate how inspection system, in which machine strength and better dimensional GKN Bad Langensalza also strength. Although the volumes are
the feedstock will flow into the mould operators have a list of inspections accuracy. Non-automotive applications account supplies MIM parts for use in much lower than in the automotive
and where the flow sections merge. which they carry out according to a The majority of GKNs MIM for roughly 10% of MIM production at prosthetic devices manufactured by industry, this is a very interesting
The data generated are then used schedule. These are then digitally products are made from low alloy GKN Sinter Metals Bad Langensalza. Otto Bock Health Care GmbH. Prior market. Bader stated that whilst
to optimise the gate position and documented. The visual inspection of and stainless steels, with these two Bicycle transmissions are a relatively to the supply of MIM components, implants are not a business area for
MIM at GKN Sinter Metals | contents page | news | events | advertisers index | | contents page | news | events | advertisers index |
Connecting Global Competence
GKN, prosthetics are a market where stage of development, thereby Marketing Manager. Two years
the company is in contact with several bringing out the maximum benefit for ago we exhibited at the Shanghai
manufacturers. new MIM applications. Automotive Show and we will be
Eighty percent of the cost of there again next year. Through these
automotive components is fixed with promotional activities GKN aims to
Focusing on Germanys the design phase, stated Schwarz. further strengthen its position as a
automotive design It is therefore so important to be major MIM manufacturer in the global
engineers involved in the process at the earliest markets.
possible stage. Later design changes
GKNs MIM development team has a are extremely difficult and costly so
Contact
strong focus on Germanys automotive chances are minimal to bring a MIM
industry. Although all of Germanys part into an approved design. GKN Sinter Metals GmbH
best known automotive brands have Cooperation with the automotive Daniel Bader
manufacturing plants worldwide, their industry has led to a trusting Am Fliegerhorst 9
main development centres are located relationship and the chance of seeing D-99947 Bad Langensalza
in Germany. The strategy for the parts go into production that have Germany
development of new MIM automotive been jointly developed over many Email: daniel.bader@gkn.com
applications starts with the targeting years is very high. This strategy has
of design engineers. been pursued for several years and
Author
Thanks to GKNs strong position in the full rewards from it are expected
the automotive components market, within the next three years due to Dr Georg Schlieper
relationships are well established the long development cycles in the Gammatec Engineering GmbH
within the departments for advance automotive industry. Mermbacher Strasse 28
developments in the automotive GKNs presence at trade D-42477 Radevormwald
industry. This close contact, according exhibitions has also been increased Germany
to Bader, is the best way to be significantly. GKN has exhibited Email: info@gammatec.com
able to influence the design of new at the Hannover Fair for the last
assemblies at the earliest possible two years, stated Susanne Htter,
The perfect recipe for success.

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| contents page | news | events | advertisers index | | contents page | news | events | advertisers index | Advances in titanium MIM
Advances in the Metal

Injection Moulding of titanium
at Euro PM2014
HZG
H E L MHO LT Z -Z EN T RUM GEEST HACHT
The Euro PM2014 conference, which took place in Salzburg, Austria,
September 21-24, presented an opportunity for the industry to review
progress to-date on global developments relating to the Metal Injection
The Helmholtz-Zentrum Geesthacht, Moulding of titanium. Dr Thomas Ebel, from Helmholtz-Zentrum
Center for Materials and Coastal Research Geesthacht (HZG), Germany, reports on a selection of key presentations
st from the event, including those with a focus on biomedical and dental
31 Augu invites you to
te m b e r 2015 applications, Metal Matrix Composites and complex 3D structures.
3 Sep ermany
u rg / G
in Lneb
Congress
PM Titanium 2015 The Powder Metallurgy (PM) of
titanium-based materials is of steadily
Biomedical applications
Biomedical applications are of
presented an interesting work on the
effect of plasma treatment before
increasing interest to both industry final sintering. The study was aiming
ongoing interest in the Metal Injection
and the research community. The at the production of stable titanium
From 31 August to 3 September 2015 the growing demand for titanium compo-
Moulding (MIM) sector. Two main
components by MIM using 70 vol%
titanium related topics were handled at
nents in the aerospace and biomedical space holders, which commonly leads
3rd Conference on Powder Processing, sectors has given rise to enhanced
the Euro PM2014 conference, namely
porous materials and beta-titanium to deformed parts. In the first part
efforts not only to reduce the costs of their work they determined the
Consolidation and Metallurgy of Titanium of raw materials and processing,
alloys based on the binary system
Ti-Nb. optimal ratio between binder, space
but also to improve mechanical and In the field of the Powder holders and metal powder. They
will take place at the Leuphana University in Lneburg, structural properties and extend the Metallurgy based manufacturing of used gas atomised Ti powder with
HZG, Ebel
near Hamburg, Germany. technological capabilities for realising porous materials there is always the a diameter smaller than 45 m and
complex and fine structures. As a challenge of retaining the geometrical rounded KCl space holders (355-
Lneburg is an ancient city from result, presentations on the PM of shape of highly porous components 500m). As binder a combination of
the Middle Ages close to Hamburg Following the very successful conferences in Brisbane/AUS (2011) titanium are a common element of during sintering. Daudt et al [1] paraffin wax, polyethylene and stearic
with picturesque houses, small and Hamilton/NZ (2013) experts on powder metallurgical processing many materials conferences.
The Euro PM2014 conference in
streets and a lot of cosy cafs and of titanium and titanium alloys will meet again for discussing status Salzburg was no different. However,
pubs. Thus, it provides an optimal
and progress on relevant PM titanium topics. unlike Euro PM2012 in Basel,
ambience for fruitful networking
Switzerland, no special interest
activities around the presentations. Further information and a Call for Papers: seminar on MIM of titanium or a
www.hzg.de/pmti2015 dedicated PM titanium session were
arranged. A variety of titanium PM
Contact: related presentations were spread
across different sessions and the
Dr. Thomas Ebel combination of PM and titanium was
Helmholtz-Zentrum Geesthacht frequently encountered in the exhibi-
Centre for Materials and Coastal Research tion hall, where producers of powders
Max-Planck-Strasse 1, 21502 Geesthacht, and processing facilities offered their Fig. 1 Porous Ti specimens with 72% solid load, without (left) and with (right)
Germany
products. plasma treatment prior to sintering [1]
Phone: +49 4152 87 1944
Fax: +49 4152 87 1920
email: pmti2015@hzg.de
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tried to avoid this by using an elastic Beta-titanium alloys based on Ti-Nb

material as the interface between Adapting the elastic properties of an implant material
punch and powder. For powder to those of cortical bone is one of the motivations for
they used spongy titanium and for research in the field of beta-titanium alloys based on
the elastic interface a disc made
from polyurethane. The effect on
Ti-Nb. Another is to avoid any potentially critical elements
such as Al as alloying additions.
Plasma Atomized
the surface can be seen in Fig.2.
Furthermore, the usage of the elastic
Bidaux et al [5] continued their previous work on
Ti-17Nb processed by MIM and presented an interesting
Spherical Metal Powders
material increased the overall porosity way to provide particularly low Youngs modulus of the
and the average pore size in a desired material. They tried to introduce the martensitic phase Designed specifically
manner. , which shows a very low elastic modulus, by rapid
Savich et al also presented a study quenching. The authors utilised gas atomised Ti powder for Additive Manufacturing, MIM,
on the usage of a mixture of spherical (Dv50= 14 m) and angular Nb powder (Dv50= 36 m). CIP/HIP & Coating processes.
and spongy powder for the production They mixed these powders with paraffin wax, low density
of permeable membrane holders, polyethylene and stearic acid as binder and processed
Fig. 2 Cross sections through pressed and sintered porous Ti material, using a
filters, aerators etc [3]. They observed the feedstock by MIM. After sintering at 1400C for 4h the
steel punch (left) and an elastic cover of the punch (right) [2]
that using only spongy powders leads porosity amounted to 4.5%. The quenching took place in Products
to a high porosity due to the intrinsic water after an additional heat treatment at 900C for 1 h.
acid was applied. After optimisation 72% solid load with and without porosity of the sponge but to a low The microstructural analysis showed no effect on porosity Titanium Grade 1
of the homogenisation process for plasma treatment. The effect was permeability in terms of gas flow. and carbides are visible as observed in other earlier Titanium Alloys Ti-6Al-4V 5 & 23
the feedstock a systematic study of analysed as being related to an However, the permeability signifi- studies on MIM processing of Ti-Nb alloys. However, a
different solid loads (72%, 75%, 80%) increased crystallinity of the polyeth- cantly increases by adding spherical clearly different picture can be observed in the SEM as Nickel Super Alloys
led to an optimal value of 80%. ylene and breakdown of polymeric powder. The effect is based on the shown in Fig. 3. Niobium
The trend was that higher solid chains due to the plasma treatment, geometrical stability of the spherical The finely distributed phase in the quenched samples
load led to increased stability. In the but an induced initial sintering of the powder particles during pressing, was identified by XRD as the desired phase. Fig.4
And Other High Melting Point Metals
second part of the work the effect titanium particles at the surface is providing a fraction of larger pores. An shows the effect on tensile properties. While the ultimate
of plasma treatment was studied.
Daudt et al compared the geometrical
also assumed. Thus, a rather stable
mantle during sintering seems to be
optimum appears to be at 70 to 80%
spherical powder.
tensile strength is not strongly affected, Youngs modulus
decreases from 76GPa to 45 GPa after heat treatment.
Features
deformation of conventionally provided by the plasma treatment, There was also a poster shown The decrease in the elongation may, on the one hand, be High purity
processed specimens with those preventing the highly fragile material with first results on the production of due to the properties of the phase but also on some
exposed to a plasma treatment before from collapsing. foams made from Ti-30Nb-13Ta-xMn
Excellent flowability
surface oxidation during quenching. Here, room for
sintering. Interestingly, they found Retaining the shape and open (x= 2, 4, 6). Guerra et al [4]. The improvement appears to exist. Few satellites
a strong effect on the geometrical porosity at the surface of pressed idea was to provide very low Youngs Amig et al [6] also worked on Ti-Nb. They added Fe Highly spherical
stability and also on open surface and sintered porous titanium was modulus of the material similar to and Cr to the alloy in order to investigate their effect on
porosity. Two different parameter sets also the aim of Savich et al [2]. The that of bone. In particular, in the study beta-phase fraction and mechanical properties. Specifi- Low oxygen content
were applied for the plasma treat- authors aimed at the production the effect of Mn on the mechanical cally, they tried to overcome the problem of inhomo- High apparent and tap densities
ment and, with the parameters 75 Pa of porous cervical and thoracic properties was investigated, showing geneous microstructures when blending and sintering
Argon, 15min, 294 W, a significantly vertebrae implants. However, they an increase of the elastic modulus elemental powder due to limited solid state diffusion.
increased stability was observed. observed undesired partial closing with increasing Mn content. Suitable For this they compared material prepared by mechanical
Fig. 1 shows a comparison of the surface pores during uniaxial material was produced by mechanical alloying with the blended elemental approach. They varied
between specimens produced with pressing by the steel punch and alloying of elemental powders. the addition of Fe and Cr in order to yield different Mo
equivalents from 8 to 12%. However, they succeeded prin-
cipally in fabricating the alloys by mechanical alloying, but
porosity was higher and mechanical properties inferior
compared to the samples prepared via blended elemental
approach. This result is probably caused by larger
particles after milling and increased hardness and less
22
deformability. Further studies are planned. Ti

47.867
Titanium
Ti-6Al-4V and Ti/ZrO2 composites

The powder metallurgical processing of titanium alloys www.advancedpowders.com
is not only interesting for bone implants but also in
sales@advancedpowders.com
the dental sector. A dental implant consists of two
parts with rather different requirements in terms of Tel: +1 450.434.1004
mechanical, optical and biological properties. The part
which is implanted into the bone should show excel-
lent osseointegration and biocompatibility plus high
Fig. 3 SEM images of the Ti-17Nb microstructure without (left) and with (right) quenching. The quenched sample was ISO 9001 : 2008 / AS 9100C
mechanical toughness. Requirements for the abutment
etched after polishing in order to reveal the martensitic structure [5]
application, meaning either in contact particles was presented by Neves et

with bone for a dental implant for al [9]. The aim was to restrict grain
example or in contact with soft tissue growth during sintering by introduc-
such as gingiva. Fig. 5 shows the tion of hard and small particles in
results for the cell migration for (a) the titanium matrix. Simply blending
the composite material compared the powders commonly results in a
to the reference Thermanox, which poor distribution of the fine particles,
is a tissue cell culture plastic being resulting in an inhomogeneous micro-
the control material used in biology, structure. Instead, the authors used
and (b) the PIM Ti-6Al-4V material a colloidal technique to distribute
compared to wrought Ti-6Al-4V and the ceramic particles on the surface
again Thermanox. of the metal powder particles before
pressing and sintering. For the study
Metal Matrix Composites spherical titanium grade 1 with a
Fig. 4 Tensile tests of as-sintered and water-quenched Ti-17Nb specimens [5] mean diameter of 10 m was used. As Fig. 6 Results for hardness and wear resistance for pure Ti-6Al-4V and particle-
Besides biomedical applications, ceramic addition the authors chose added material [8]
a b there were numerous papers on the fine alumina and zirconia powders,
addition of particles to standard tita- the latter one in two variations,
nium materials, some of them aiming namely monoclinic (m-ZrO2) and For all variants including pure In contrast, the Al2O3-containing
directly at Metal Matrix Composites tetragonal yttria-stabilized (t-ZrO2). Ti granules measurements on the composite behaves differently; the
(MMCs). One interesting way to form The Dv50 value of the powders was dependence of the relative green ceramic particles appear to dissolve
MMCs was presented by Biasetto et al between 300 and 400 nm. Suspen- density on the compacting pressure during sintering, so aluminium and
[8]. In this study preceramic polymers sions were made with KNO3 addition were performed and the results oxygen atoms are distributed in the
were used for the in-situ forming and pH-adjusted by using tetra methyl showed excellent compressibility even Ti-matrix and no particles are visible
of silicides and carbides in order to ammonium hydroxide (TMAH) and for the ceramics-including granules, at the grain boundaries. In all cases
improve hardness and wear resist- HNO3 solutions. From each ceramic especially the variant with t-ZrO2. Vickers hardness of the material
ance of Ti-6Al-4V. For metal powders, powder water based slurries were After sintering the total porosities increases significantly compared to
Fig. 5 Cell migration on Ti/ZrO2 (a) in contact with epithelial tissue and
equal portions of two size fractions fabricated by mixing 1 wt% of the were 8.5% (Ti-m-ZrO2), 7.3% (Ti-t- the pure titanium material (Fig. 8). As
PIM Ti-6Al-4V (b) in contact with bone tissue in comparison with reference
of gas atomised Ti-6Al-4V powder ceramics with 50 vol% Ti powder, ZrO2), 3.7% (Ti-Al2O3) and 4.8% (pure reasons for this behavior the authors
materials [7]
were mixed (-250 m and -45 m). where ammonium polyacrylate (PAA) Ti). The microstructures were very attribute the total oxygen content,
Then poly(methylsilsesquioxane) was was used as dispersant. High power homogeneous. Interestingly, the smaller grain size and lower closed
on the other hand are hardness feedstock. Because of different added which decomposes at around ultrasound was applied to the slurries investigation of existing particles in porosity.
and good aesthetics. Furthermore, binders the debinding processes for 350C. Under Ar or N atmosphere it to avoid agglomerations. As binder, the Ti-matrix after sintering revealed
the growth of bacteria should be Ti-6Al-4V and Ti/ZrO2 were different, transforms to SiOxCy ceramic phases. polyvinyl alcohol (PVA) was used. After significantly different behavior of the Improving mechanical
suppressed, while good adhesion of but the sintering temperatures were The polymer was crosslinked by a spray-drying, cylinders were produced different composites. In the case of properties
epithelial tissue is desired. Thus, two quite similar. Ti-6Al-4V was sintered catalyst and added (9 vol%) to the by uniaxial pressing and subsequently Ti-m-ZrO2 corresponding ceramic
different materials are required and at 1350C for 1 h, while the composite metal powder together with 1 vol% sintered at 1100C for 30 min under particles were found mostly at the Reinforcement of Ti-6Al-4V and
former studies showed that Ti-6Al-4V was sintered at 1300C for 3 h. In view PEG. Then the mixture was milled in vacuum. Fig. 7 shows the Ti-Al2O3 grain boundaries, while in the case increase of its Youngs modulus in
is suitable for the implant section, of 2C-PIM all these parameters and a planetary ball-mill with the milling granules after spray drying and the of Ti-t-ZrO2 Y2O3 particles are formed order to provide mechanical proper-
while for the abutment a composite binders have to be adapted appropri- parameters as one subject of the dispersion of the ceramic particles on and found at the grain boundaries, ties closer to those of high-strength
made from titanium and zirconia ately, but this should not in principle investigation. the surface of the Ti spheres. thus, Zr is dissolved in the matrix. steels or Ni-based alloys is the
appears to be adequate. Because be a problem. Cytotoxicity experiments The milled material was shaped
size and geometry of dental implants using organotypic cultures were into discs by uniaxial pressing and
are generally standardised, Powder conducted on the sintered materials sintered at 1400C for 2 hours under
Injection Moulding (PIM) appears to and compared with other reference argon. XRD-measurements confirmed
be a promising technique for both materials with wrought surgical the impression of SEM and EDS
parts. Additionally, two component Ti-6Al-4V (ASTM F 136 standard). investigations that well distributed
(2C) Powder Injection Moulding could The trend for the PIM Ti-6Al-4V silicides and carbides were formed
be applied, avoiding any additional material was to show in contact with during the process. EBSD measure-
joining process. chick embryo bone increased cell ments identified the carbides as
Auzene et al [7] reported on migration and adhesion compared TiC and the silicides as Ti5Si3. Fig.6
the biocompatibility of materials to the references. In the case of shows the effect of the particles on
produced by PIM from Ti-6Al-4V the composite in contact with chick hardness and wear resistance. The
and Ti/ZrO2 composite, respectively. embryo skin, interestingly, cell growth hardness increased by about 12%
They used commercial feedstocks was significantly reduced, while a while the wear resistance improved
as raw material. For the composite good adhesion of epithelial tissue was dramatically.
they mixed 90 wt% titanium grade4 observed. Thus, both materials appear Another method for providing a
feedstock with 10 wt% zirconia to be appropriate for their intended homogeneous distribution of ceramic Fig. 7 SEM images of titanium/Al2O3 granules after spray drying [9]
(<25m). As a result of the process

sketched in Fig.9 an improved
interface between reinforcement
particles and titanium matrix was
gained.
Densification was performed by
SPS after mixing the reinforcement
with more Ti-6Al-4V powder. Two
variants of the final composition
were fabricated, namely 10 vol% and
20 vol% TiB and TiC, respectively.
The basic processing parameters for
SPS were a maximum temperature
of 1100C for 2 min under vacuum
of 10-2 Pa. Typical microstructures
of the sintered material are visible Fig. 11 Microstructures of MIM processed Ti-6Al-4V and Ti-6Al-4V + 0.2 Y2O3 [11]
Fig. 8 Vickers hardness as a function of added ceramics and oxygen content [9]
in Fig. 10, where a significant
grain refinement can be observed
to restrict grain growth in Ti-6Al-4V during sintering by
(around 20-30 m) compared to pure
adding small ceramic particles. They applied uniaxial
Ti-6Al-4V. While the TiB particles
pressing and MIM for the processing of spherical
are distributed quite uniformly over
Ti-6Al-4V powders (< 45 m) and mixed these powders
the matrix, the carbides appear to
with 1 wt% of different oxide particles (MgO, CeO2, ZrO2,
be mostly at the grain boundaries.
Y2O3 and CaO, sizes between 200 and 600nm) during
For all composites the density
feedstock production. As binder a mixture of paraffin
was higher than 99% of the theo-
wax, polyethylene-vinylacetate and stearic acid was used.
retical value. The Vickers hardness
The MIM feedstock was also used for the production
increased from 324 (pure Ti-6Al-4V)
of uniaxial pressed cylinders. Sintering was performed
to a range from 433 (10 vol% TiB) to
under vacuum for 2h at 1350C. In all cases, other than
541 (20 vol% TiC). First mechanical
the variant with yttria addition, the porosity after sintering
tests reveal a significant increase of
was around 3 to 3.5%. Adding yttria led to a high porosity
the Youngs modulus to about 170
of 12.3%. However, a dramatic decrease of the colony
GPa for the composites with 20 vol% Fig. 12 Tensile tests of MIM processed Ti-6Al-4V plus
size to 25 m compared with 130m of pure Ti-6Al-4V
reinforcement. different oxide particles [11]
Fig. 9 Production scheme of reinforcement particles [10] was observed. By a reduction of the yttria content to
Fatigue resistance is an essential
0.2% and 0.1%, the porosity was reduced to 6.1% and reproducibility of commercially fabricated components.
property for application under
3.4% and the colony size amounted to 30 m and 50 m, Because of confidentiality, no details of feedstock and
motivation of the work of Agote et Synthesis (SHS) using highly-loaded dynamic load. PM processed
respectively. All additions of ceramic particles resulted in process were given, but the mechanical data exceeded the
al [10]. They added TiB and TiC, master alloys of around 80% of material tends to show inferior
a reduction of the colony size, but the strongest effects ASTM F2885 for MIM fabricated medical components from
respectively, to Ti-6Al-4V powder and TiB and TiC respectively, mixed behaviour compared to wrought
were observed in the case of yttria and CaO (40 m). For Ti-6Al-4V by a considerable margin. After MIM processing
compacted the mixtures by Spark with Ti-6Al-4V. The raw materials material due to residual porosity and
these compositions tensile test specimens were made and subsequent HIP treatment average values for yield
Plasma Sintering (SPS). The strength- were fine irregular boron (< 5 m) different microstructure, especially
by MIM and tested. Fig. 11 shows the microstructures of strength, ultimate tensile strength and plastic elongation
ening particles were produced by and carbon (< 0.5 m) powders with larger grain size. Limberg et
pure Ti-6Al-4V and Ti-6Al-4V + 0.2 Y2O3. were 860 MPa, 964 MPa and 19.8% respectively. Oxygen
Self-propagating High-temperature and spherical Ti-6Al-4V powder al [11] investigated the possibility
The specimens containing 0.1% and 0.2% yttria content was about 1700 g/g. The mechanical properties
showed high plastic elongation of around 15% and equal practically those commonly known from wrought
strength comparable to pure Ti-6Al-4V, while the CaO Ti-6Al-4V. This is even true for the endurance limit of
containing specimens showed high strength, but brittle around 620 MPa at 10 million cycles. According to the
behaviour (Fig. 12). The microstructural investigation authors the good fatigue properties are the results of an
revealed that the CaO particles decompose during optimised microstructure.
sintering and the atoms are dissolved in the matrix.
The oxygen atoms in particular harden, but embrittle,
3D titanium structures
the material as seen in the tensile test. Thus, the best
candidate for grain refinement appears to be Y2O3, Piemme et al also introduced an interesting technique for
according to this study. the production of 3-dimensional complex structures, for
Piemme et al [12] showed that Ti-6Al-4V processed example as a tissue integration layer for bone implants.
by MIM can show excellent mechanical properties, They utilised sacrificial inserts to form structures during
including fatigue resistance, if all individual processes the injection moulding process. The inserts can be made
are carefully and consistently mastered and the fabrica- by Additive Manufacturing techniques, so the freedom of
tion is limited to the processing of titanium alloys. They geometry is very high. After production, they are inserted
Fig. 10 Microstructures of the sintered material, left: TiB added, right: TiC added Ti-6Al-4V [10] presented mechanical data and their corresponding in the mould and the feedstock is injected around and into
are possible. It is a layer by layer technique and its steps a comprehensive presentation on
are outlined in Fig. 14. EBM in the programme of the Special
As with MIM, a powder-binder mixture is used. The Interest Seminar on Progress in
authors applied gas atomised Ti-6Al-4V powder with a Additive Manufacturing. He pointed
particle size smaller than 25 m and an organic and water out that although the mechanical
soluble binder. For the production of the part the struc- properties of Ti-6Al-4V processed
tured screen is positioned on a substrate and the printing by EBM yield excellent values, there
paste is applied, so one layer of the part is produced. is still no breakthrough in terms of
After drying the next layer is fabricated by repeating the commercial application. He showed
process with the same screen or by changing the screen a that tensile (Fig. 17) and fatigue (Fig.
change in the geometry can be performed. After forming, 18) properties are in the range of Fig. 14 Scheme of the 3D screen printing technique [13] Fraunhofer IFAM
the parts are debound and sintered in the usual manner wrought material if the process is Dresden
known from MIM. properly performed. For example, the
The rheology of the paste is extraordinarily important typical forming of microstructural
for the success of the process, so the formulation of the columns during EBM processing can
printing paste was one of the subjects for investigation be reversed by subsequent heat treat-
in the study presented. Different components such as ment such as HIP, with the additional
surfactants and defoaming agents have to guarantee a benefit that any pores are closed.
homogeneous paste. The authors determined a paste with However, concerns exist on the
a powder loading of 43 vol% being most suitable. After the one hand because of defects inherent
sintering of test patterns such as those shown in Fig. 15 in the usage of powders and in the
at 1250C for 1 h under vacuum the typical basketweave process. Examples of defects are
structure of alpha and beta phases were observed as the porosity or inclusions in the powder,
microstructure. However, oxygen and carbon contents lack of fusion or delamination during
were rather high, so some studies for improvement will be deposition, different microstructural
performed in the future. orientations in the build, for example
The Additive Manufacturing of components from connected with turning points or heat
Ti-6Al-4V was the third technique presented for the sinks and even errors in the STL files.
production of 3D structures. Kirchner et al [14] performed Most of the defects can be controlled
a study on the process window for Electron Beam Melting to a greater or lesser extent, but not Fig. 15 Test structures fabricated by 3D screen printing (green, brown and
(EBM). The aim was to optimise process parameters such avoided completely. So, on the other sinter state) [13] Fraunhofer IFAM Dresden
as scan speed and beam current in relation to build rate, hand, there is a lack of understanding
geometrical stability and mechanical properties. For the related to processing conditions and
investigation they used gas atomised Ti-6Al-4V powder in their effect on materials properties
the range of 45 to 105 m. During the work, the authors which has to be overcome by more
recycled the powder up to ten times and observed just a basic scientific studies. As one
small increase in oxygen. In each process ten parts of 50 example Todd showed detailed
mm x 10 mm x 14 mm were fabricated and investigated. investigations on fatigue behavior
In terms of density a decrease with increasing scan based on x-ray computer tomography.
speed was determined including a sharp drop at a certain
Fig. 13 3D structures fabricated by MIM and use of a limit. When scan speed was too low in connection with Other Ti-based materials
sacrificial insert [12] a high beam current swelling of the top surface and
enhanced aluminium loss was observed. In contrast, the Besides Ti-6Al-4V there were a few
the part. After moulding the insert is removed in a similar porosity of 0.25% was nearly independent of the process presentations on other titanium
way to spaceholders in porous materials and the part parameters and appeared to be caused by gas inclusions materials. The use of titanium
is sintered. The technique is also suitable for providing in the powder particles. The microstructure showed hydride was the subject of the work
special surfaces, for example in terms of roughness. isotropic characteristics with a dependence of the size of presented by Petroni et al [15]. The
Fig.13 shows an example of an ingrowth surface (a) along alpha plates on the scan speed. Nearly 100% martensitic motivation for the use of hydride
with a close-up (b). A layer with finer porosity and organic alpha phase was produced if the scan speed was high powders is the lower cost and the
Fig. 16 Process window for EBM processing of Ti-6Al-4V powders [14]
appearance is shown in (c). enough. For reasonable parameter sets the ultimate good compacting properties. The
The realisation of 3D structures by means of Powder tensile strength was between 970 and 1030 MPa combined authors performed a hydriding
Metallurgy techniques was the subject of two more studies with more than 10% elongation. A certain limit was also treatment of Ti sponge fines and to separate the influences of initial parameters the authors observed a
presented at Euro PM2014. Jurisch et al [13] worked on detected for the beam current; if the value was too small sieved two fractions, < 355 m and density, sliding and fracture, and good agreement between model and
a special variant of screen printing which is commonly a sudden drop in density occurred. Fig. 16 represents the < 150 m respectively. The powders elastic and plastic deformation on experimental data. They concluded
utilised for the production of solar cells or piezoelectric process window for scan speed and beam current as the were uniaxially cold pressed and the the final green density. Furthermore, that the initial density is the most
devices. It combines MIM and Additive Manufacturing result of the study. A good quality can be produced in the compaction behaviour compared with they compared the results with the important factor in determining the
for the production of miniaturised intricate parts in high parameter field between 100 and 200 J/m. a theroretical model developed by usage of commercial HDH powder. final density. However, in the case of
numbers. Even inner structures such as closed channels Iain Todd, from The University of Sheffield, UK, gave Gerdemann and Jablonski in order After determining the right fitting HDH powder also sliding and fracture
particle size smaller 45 m was mixed

with a binder consisting of paraffin a b
wax, polyethylene-vinylacetate and
stearic acid. From this, specimens
for compression and tensile creep
test as well as for tensile tests were
produced. Sintering took place at
1500C for 2 h and a very low porosity
of around 0.5% was yielded. The
authors varied the cooling rate from
sintering temperature and by this
changed mainly the width of the
lamellae and the grain size of the
microstructure. The effect on creep
resistance is quite strong, as shown
in Fig. 19. While for tensile strength Fig. 19 Creep curves of MIM processed Ti-45Al-5Nb-0.2B-0.2C (TNB-V5) with different cooling rates applied. Left:
the fast cooling (100K/min) showed tensile creep, right: compression creep [16]
the highest value (560 MPa), for creep
resistance slow cooling is beneficial,
probably because of the larger grains. References Martinez, V. Amig, Microstructural [15] S.L.G. Petroni, E.T. Galvani, C.A.A.
Characterization of Ti-Nb-(Fe-Cr) Cairo, C.C. Girotto, V.A.R. Henriques,
Compression creep tests were also
Fig. 17 Typical tensile properties (UTS) of Ti-6Al-4V processed by different The papers reviewed in this report are Alloys Obtained by Powder Metallurgy. Compaction and Densification Behav-
performed with arc-melted material
techniques (Data sources: Titanium, A Technical Guide, M. Donachie, Arcam AB published in the proceedings of the [7] D. Auzene, T. Jacquemin, J.L. iour of Titanium Hydride Powder.
representing an as-cast condition. As
and University of Sheffield) Euro PM2014 conference, Salzburg, Duval, C. Egles, J.M. Popot, Biological [16] T. Ebel, J. Soyama, M. Oehring, F.
Fig. 19b reveals, the slow cooled MIM
Austria, 21-24 September 2014, and Characterization of Materials Pyczak, K.U. Kainer, Creep resist-
specimens showed even better creep
organised by the European Powder Produced by Powder Injection ance of intermetallic TNB-V5 alloy
resistance. Thus, MIM of titanium
Metallurgy Assiciation (EPMA), Moulding (PIM) for Dental Applica- processed by Metal Injection Moulding
aluminides appears to be competitive
Shrewsbury, UK. tions.
with casting, particularly in terms of
creep properties. [8] L. Biasetto, F. Bonollo, A. Fabrizi,
[1] N F Daudt, L. Classen, M Bram, Author
P. Colombo, Development and
H P Buchkremer, Manufacturing of
Outlook Characterization of Ti6Al4V Matrix Dr. Thomas Ebel
Highly Porous Titanium Samples by Composites, Formed In Situ via the Helmholtz-Zentrum Geesthacht
As shown in this report, Euro PM2014 MIM with Temporary Space Holders. Preceramic Polymer Route. Centre for Materials and Coastal
featured a wide variety of contribu- [2] V V Savich, A I Shelukhina, G [9] R. G. Neves, B. Ferrari, A.J. Research
tions related to titanium. However, A Sheko, A M Taraykovich, S A Sanchez-Herencia, and E. Gordo, Max-Planck-Strae 1
PM titanium suffers from a rather Bedenko, Formation of Anisotropic Design of Ti Microstructure by Addi- D-21502 Geesthacht
small community compared to steel Structure of Porous Vertebral tion of Ceramic Particles by Colloidal Germany
processing. Thus, at PM conferences Implants by Compating Spongy Techniques. Tel: +49 (0) 41 52 / 87 - 1944
titanium is usually a relatively small Titanium Powder through the Elastic Email: thomas.ebel@hzg.de
[10] I. Agote, M.A. Lagos, Study on the
subject whilst at titanium conferences Punch Facing. www.hzg.de
Effect of Processing Method and Type
Powder Metallurgy is featured in [3] V V Savich, A M Taraykovich, S of Reinforcements on Titanium Matrix
a rather minor way. Specialised
Fig. 18 Typical fatigue properties of Ti-6Al-4V processed by different techniques A Bedenko, Porous Permeable Composite Properties.
meetings are therefore important as
(Data sources: Titanium, A Technical Guide, M. Donachie, Arcam AB and Materials from Titanium Powders with
the Ti Powder Metallurgy conference [11] W. Limberg, T. Ebel, K.U. Kainer,
University of Sheffield) Various Particle Shapes.
first held in Brisbane, Australia, in Addition of Rare Earth Elements to
December 2011, first demonstrated. [4] C Guerra, C Aguilar, D Guzmn, MIM-Processed TiAl6V4.
and deformation play a role, rather shaping is very difficult, thus PM Here, PM titanium specialists from P A Rojas, S Lascano, L Perez, [12] J.A. Grohowski and J.C. Piemme,
different to the just hydrided powder. methods are interesting - including the whole world met and the confer- Production and Characterization Titanium MIM: Technology for Medical
In all cases deformation is more MIM for smaller components. ence was continued successfully in of Mechanical Properties of Ti-Nb- Device Manufacturing.
important than sliding and fracture. Ebel et al [16] assessed the creep December 2013 in Hamilton, New Ta-Mn Alloy Foams for Biomedical
[13] M. Jurisch, T. Studnitzky, O.
The creep properties of MIM properties of MIM processed Zealand. The event will be held Applications.
Andersen, B. Kieback, 3D Screen
processed titanium aluminides were Ti-45Al-5Nb-0.2B-0-2C (all contents again this year, from August 31 to [5] J.-E. Bidaux, R. Pasquier, M. Printing for the Fabrication of Small
the topic of the last study presented in in at%), also known as TNB-V5 alloy. September 3 2015. in Lneburg, Rodriguez-Arbaizar, H. Girard, E. Intricate Ti-6Al-4V Parts.
this report. These variants of titanium They focussed on the primary creep Germany. Carreo-Morelli, Low Elastic Modulus
alloys intended for high-temperature because this is often the limiting [14] A. Kirchner, B. Kloden, J. Luft,
Ti-17Nb Processed by Powder
applications suffer from brittleness factor for technical applications of T. Weigarber, B. Kieback, Process
injection Moulding and Post-Sintering
and hardness of the intermetallic this material class. For the feedstock Window for Electron Beam Melting of
Heat Treatment.
phases they consist of. Conventional pre-alloyed TNB-V5 powder with a Ti-6Al-4V.
[6] A. Amig, J. Zambrano, S.
| contents page | news | events | advertisers index | | contents page | news | events | advertisers index | Magnesium PIM
Developing the Powder Metallurgy Future european powder
metallurgy association
PIM at Euro PM2014:
Magnesium Powder Injection
Limited Exhibition Moulding for biomedical
Space Available applications
A keynote paper at the Euro PM2014 congress presented by Martin
Euro PM2015 Congress & Exhibition Wolff, Helmholtz-Zentrum Geesthacht (HZG), Germany, discussed
the viability of processing medical implants from magnesium alloys
4 - 7 October 2015 by Powder Injection Moulding. Magnesium is of particular interest
for medical implant applications thanks to, amongst other things, its
Reims Congress Centre, Reims, France excellent biodegradability and biocompatibility. Dr David Whittaker
reviews the paper for PIM International.
Image courtesy of Euro PM2014-wildbild

Research into the processing of and 36 months, poor mechanical completely, shows mechanical
magnesium via Metal Injection properties and acidic degradation properties matching those of cortical
Moulding (MIM) at Helmholtz- behaviour. bone tissue and consists of the
Zentrum Geesthacht, Germany, has It was stated that magnesium nontoxic elements Mg and Ca which
been the subject of two previous alloys are drawing increasing are needed in the human body. The
reports in PIM International (Vol. 2 interest as biodegradable medical corrosion behaviour of Mg enables a
No. 2 June 2008, 63-65 and Vol. 6 implant materials for orthopaedic well-directed biodegradation and the
No. 4 December 2012, 59-63). In the applications in bone tissue, thus, a corrosion products generated during
keynote paper in the Biomaterials replacement of polymers by Mg would biodegradation in bone tissue have
session at Euro PM2014, Magnesium be attractive. The newly developed been identified as being non-cytotoxic.
Powder Injection Moulding for magnesium-based biodegradable The production of biomedical and
Biomedical Applications, by M Wolff, and biocompatible material degrades biodegradable Mg alloy parts and
T Ebel and K U Kainer (Helmholtz-
Zentrum Geesthacht), J G Schaper
Images courtesy of IFAM
and M Dahms (University of Applied

Sciences, Flensburg, Germany) and T
Klassen (Helmut Schmidt University,
Hamburg, Germany), updated
information was given on how
magnesium powder can be processed
successfully by MIM.
Currently, commercial
biodegradable implants are generally
made from degradable polymers
such as polyglycolic acid (PGA)
or polylactide acid (PLA). These
polymer implants, produced by
injection moulding, suffer from long Fig. 1 Time-temperature-pressure diagram of the magnesium sintering
degradation times of between 18 process for MIM parts
62 www.europm2015.com
Powder Injection Moulding International March 2015 2015 Inovar Communications Ltd Vol. 9 No. 1 Vol. 9 No. 1 2015 Inovar Communications Ltd March 2015 Powder Injection Moulding International 63
Magnesium PIM | contents page | news | events | advertisers index | | contents page | news | events | advertisers index | Magnesium PIM
implants by MIM could potentially sintering, leads to the formation of a However, a recent study has shown sintering in a hot wall furnace. The
offer the opportunity for economic thermodynamically stable MgO-layer that EVA is not adequate for MIM of thermal debinding step took place
manufacturing of parts with and Mg2(OH) on the surface of the Mg due to its oxygen rich acetate under protective argon gas flow
mechanical properties matching powder particles. group in the molecular chain. In of 0.5 litres/min at 5 to 20 mbar.
those of cortical bone tissue as well This paper described how this contrast, the copolymer component Fig. 1 shows the complete time-
as the provision of porous surface challenge could be met at each stage binder, Poly(propylene-co-1-butene), temperature-pressure diagram of the
structures beneficial for cell ingrowth of the MIM process route, to provide a PPco1PB, highlights the possibility process.
and vascularisation. Furthermore, the viable manufacturing process capable of residual-free thermal debinding In sintering, by adding the calcium
technique guarantees a homogenous of delivering parts with attractive and enables sintering of magnesium. to the powder material in the form
microstructure, which is crucial for a properties. Hence, PPco1PB was used as of a gas atomised Mg-Ca-master (a) (b)
predictable degradation process. backbone copolymer in this study. alloy powder (MAP) containing 5 wt%
However, processing of magne- However, the previous study had Ca, an improved sintering density Fig. 4 (a) SEM-BSE image of the microstructure of a MIM Mg-0.9Ca (X1)
Feedstock preparation
sium by any powder metallurgical shown that the polymer content was achieved by the formation of a specimen. (b) The rectangular area displays the part at higher magnification
route is beset with significant In feedstock preparation, organic of PPco1PB has to be chosen to liquid phase. The utilised powder and resolution
challenges, related to its strong polymer binders can act as additional be as low as possible to ensure mix, therefore, contained the
affinity for oxygen and the fact that sources of oxygen and carbon. Poly good sintering behaviour. Hence, constituents pure Mg powder and
the Mg-matrix shows, in contrast Ethylene Vinyl Acetate (EVA) is well the volume percentage of binder MAP powder. The MAP-route enables
to other materials with high affinity known and commonly used at the components in the powder matrix was the fractional melting of the MAP
for oxygen such as titanium, no Helmholtz-Zentrum Geesthacht as set between 35 vol.% and 36 vol.%. below the sintering temperature, Ts.
solubility for oxygen atoms. Oxygen a backbone copolymer compound Apart from thePPco1PB backbone The calcium-rich liquid phase helps
uptake during processing, especially for the MIM of titanium alloys. binder, the binder system in the in destabilising the Mg oxide layer
feedstock also contained paraffin wax and initiates the sintering process.
and stearic acid. Fig. 2 (a) demonstrates schematically
The powder blending to a how liquid phase sintering in the (a) (b)
Mg-0.9Ca powder mixture and the powder compound occurs. Sintering
Fig. 5 (a) Mg-0.9Ca (X1) as sintered and (b) as cast
subsequent feedstock preparation takes place a little above the solidus
took place under an atmosphere of temperature of the alloy composition.
Tensile test results MIM Mg X1 Cast Mg X1 [38] PLA
commercial argon 4.6 in a glove box Therefore, a permanent liquid Ca-rich
system to avoid any additional oxygen phase occurs during sintering and Ultimate tensile strength [MPa] 131 2.9 98.8 7.8 49-78
pick up. The powder and polymer ensures a safe consolidation of the Tensile yield strength [MPa] 64 1.8 81.3 2.3 -
components were placed into the compound. Fig. 2 (b) and (c) demon-
mixing crucible and were heated up strate clearly how molten MAP coats Elongation [%] 6.8 1.8 4.1 1.4 3-5
to the melting temperature of the magnesium particles and infiltrates Youngs modulus [GPa] 19.4 12.6 - -
polymers. This was the last process the magnesium matrix.
Residual porosity [%] 2-6 0 0
step under the protective argon Also essential for successful
(a) (b) (c)
atmosphere. Following this, the sintering is a labyrinth-like crucible Average grain size [m] 23.3 1.3 350.4 129.3 -
Fig. 2 (a) Detail of Mg-Ca phase diagram [27], green arrow shows diffusion path mixing to a homogeneous feedstock setup, as illustrated schematically
Table 1 Mechanical properties of MIM Mg-0.9Ca (X1) tensile test specimens in
of MAP into Mg (b) SEM-SE image of a Mg-particle which is partly coated with within five to ten minutes took place in Fig. 3(a). The crucible consists of
the as-sintered condition in comparison with their as-cast counterparts and
Master Alloy (c) SEM-BSE image of Ma base material and molten MAP which in a planetary mixer, which was an outer casing and inner crucibles
PLA (polylactide acid)
infiltrates the Mg powder matrix placed in the laboratory outside the made of unalloyed steel. The outer
glove box system. casing was filled with pure irregular
magnesium powder as an oxygen cold area of the hot wall furnace. This of the powder compact with the
getter. All specimens were placed can lead to a sealed cold area of the typical residual porosity of a MIM part.
Processing route
inside the inner crucibles as shown combined debinding and sintering Table 1 compares the material prop-
In moulding, optimal powder in Fig. 3(a). The getter was used to furnace as shown in Fig. 3(b). The erties of sintered MIM Mg-0.9Ca (X1)
loading is essential for defect-free protect thermally debound brown best sintering results were derived by with those of its as-cast counterpart
green part production. The optimal parts from picking up additional using a short-term vacuum sintering and those of polylactide acid. Despite
minimum powder loading was found oxygen during sintering. The getter following by longer-term sintering a residual porosity between 2 and
to be 64 vol.%. At powder loadings bed was used to generate a gaseous under ambient pressure conditions. 6%, the ultimate tensile strength and
above65vol.%, the mould filling Mg-vapour atmosphere, with high elongation of the sintered material
ability decreases. oxygen affinity, inside the sinter are significantly higher than those of
After the moulding of green parts, crucible. This Mg vapour-shield
Material properties
the as-cast material. This result can
(a) (b) the organic binder was removed from protects any inner specimens from Following the defined process route, be explained by the different grain
the parts by solvent and thermal external oxygen. However, a potential the material properties achieved with sizes of the materials. Fig. 5 displays
Fig. 3 (a) Schematic illustration of the labyrinth-like crucible configuration, red debinding. After solvent debinding disadvantage of this method is the MIM X1 (Mg-0.9Ca) parts are shown the grain size of Mg-0.9Ca in the
arrows displays the path of oxygen impurities (b) Resublimation of magnesium and drying, the debound green parts partial formation of ultra-high purity in Table 1. The microstructure of as-sintered condition in comparison
at the cold area of the recipient of the hot wall furnace and inside of the heat were put into the sinter crucible for magnesium resublimation crystals the MIM part is shown in Fig. 4. This to the as-cast condition. The material
shielding combined thermal debinding and inside the sinter crucible and the figure proves successful consolidation properties of MIM X1 also significantly
Magnesium PIM | contents page | news | events | advertisers index | | contents page | news | events | advertisers index |
good and exceed those of biodegrad- May 1719, 2015 SAN DIEGO
45 able polymer materials by over 80%.
The resublimation effect of getter
Youngs Modulus [GPa]
40
material inside the furnace and onto
35
Additive Manufacturing
the specimen material itself was also
30
apparent in some instances. This
25 effect seems to be initiated through
temperature differences between the
with Powder Metallurgy

20
15
specimen and the crucible material.
Hence, the effect can be avoided in
0% 5% 10% 15% 20% 25%
the future through understanding
Residual porosity [%] the exact temperature differences
inside the crucible during operation. May 1719, 2015 San Diego, CA
Fig. 6 Linear relationship between porosity and elastic modulus Nevertheless, the aim of this study
was to complete the process chain
Sintering temperature Ts [C] and time ts [h] from the feedstock preparation to the
sintered part and this can be claimed
Vacuum Atmosphere
Ts/ts Ts/ts to have been done successfully.
In addition to rectangular bars
Group 1 635/2 -
Group 2 635/4 -
and tensile test specimens, some
more complex biomedical implant
Focusing on additive manufacturing with
Group 3 645/2 640/62
screw prototypes were also produced powder metallurgy (PM), this conference
successfully as shown in Fig. 7. This
Table 2 Detailed sintering parameters relating to groups 1, 2 and 3 in Fig. 6 part of the study proved the general will feature worldwide industry experts
suitability of magnesium based
powders for the MIM production of
presenting the latest technology
surpass those of polylactide acid,
which is currently in common clinical
highly porous magnesium parts can
be produced with corresponding low
fragile and complex shaped parts. developments in this fast-growing field.
use as a biodegradable orthopaedic modulus of elasticity. The curve also The full version of this paper is avail-
implant material. illustrates that the chosen Mg alloy able in the Euro PM2014 Congress
Due to local plastic deformation can provide an elastic modulus of Proceedings, published by the EPMA.
in micro-areas around pores or other around 45 GPa in the dense condi- It is also published in Powder Metal- Perspectives from:
low strength particles, the elastic tion. Table 2 shows the sintering lurgy, Vol. 57 No. 5, 331-340.
regions of the measured stress-strain parameters of these three specimen
metal powder producers
curves were not exactly linear and, groups in more detail, according toll providers
therefore, dynamic Youngs modulus to sintering time, temperature and
Contact end users
was also measured non-destructively furnace pressure. Dipl.-Ing. Martin Wolff equipment manufacturers
using an ultrasonic resonance The parts produced to-date contain Helmholtz-Zentrum Geesthacht R&D from academia and consortia
method. The diagram in Fig. 6 shows a number of types of moulding Centre for Materials and Coastal
the impact of sintering parameters defects. Despite these defects, the Research, Max-Planck-Strae 1
Topics will cover:
on the residual porosity and elastic material properties of the presented D-21502 Geesthacht, Germany
modulus of the sintered parts. Hence, MIM magnesium material are very Email: martin.wolff@hzg.de materials
applications
technical barriers
process economics
new developments
Exhibition:
trade show featuring leading AMPM suppliers
Held in conjunction with:
CONFERENCE CHAIRMEN:
Fig. 7 Implant prototypes made from Mg X1 Feedstock in the green and sintered conditions green (left image). The
David K. Leigh, Harvest Technologies, A Stratasys Company
threads cutting edge, shown in the middle SEM-image, has a thickness of only 100 m. The right hand side image shows
Joseph T. Strauss, HJE Company, Inc.
the microstructure with its typical residual porosity as well as the typical smooth surface roughness of a MIM part in the
as-sintered condition POWDERMET
2015 For program and further information contact the conference sponsor:
MAY 1720
0 MPIF/APMI
/
Metal Powder Industries Federation
SAN DIEGO 105 College Road East, Princeton, NJ 08540 or visit AMPM2015.org
| contents page | news | events | advertisers index | | contents page | news | events | advertisers index | PIM microstructural studies
PIM at Euro PM2014:

Microstructural studies of
advanced Powder Injection
Moulded materials
In our final report from the Euro PM2014 congress, Salzburg, Austria,
September 21-24, Dr David Whittaker reviews two papers which report on
microstructural studies of advanced PIM materials. The first paper presents
work undertaken on the PIM of metal-ceramic interpenetrating phase
composites, whilst the second paper reports on a microstructural evaluation
of MIM HK-30 stainless steel, a material with high growth potential thanks
to the rapidly increasing use of automotive turbochargers.
Powder Injection Moulding of there are two matrices intertwined property combinations are of interest
metal-ceramic interpenetrating three-dimensionally and penetrating for a variety of applications, including
phase composites each other (Fig. 1). Due to this type of surgical instruments and grinding
In his Euro PM2014 keynote structure, IPCs offer the possibility of tools.
presentation Dr Sebastian Hein, combining typical ceramic properties, Metal-ceramic IPCs are usually
from Fraunhofer IFAM, Germany, such as high hardness, stiffness produced by infiltration of a porous
addressed the topic of the Powder and abrasion resistance, with typical ceramic structure with a molten
Injection Moulding (PIM) of metallic properties such as fracture metal and this may be achieved by
metal-ceramic interpenetrating toughness and thermal and electrical capillary driven metal infiltration,
phase composites. The structure conductivity. Materials with such gas pressure assisted infiltration
of a composite material is a very
important property-determining
factor and so composite materials are
Download your FREE often differentiated according to their

structure. A distinction can be drawn
between particle-reinforced compos-
digital copy of the latest

ites, fibre-reinforced composites,
laminates and interpenetrating phase
composites (IPCs).
issue at www.ipmd.net
This distinction is based on the
dimensionality of the dispersed phase
of the composite, which is zero-
dimensional for particles, one-dimen-
sional for fibres, two-dimensional
POWDER
for layers and three-dimensional for
IPCs. In the case of IPCs, there is Fig. 1 Schematic depictions: (left) particle-reinforced composite structure,
METALLURGY no actual dispersed phase; instead, (right) interpenetrating phase composite (IPC) structure [1]
68
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Powder Injection Moulding International March 2015
REVIEW
Vol. 9 No. 1
2015 Inovar Communications Ltd Vol. 9 No. 1 2015 Inovar Communications Ltd March 2015 Powder Injection Moulding International 69
PIM microstructural studies | contents page | news | events | advertisers index | | contents page | news | events | advertisers index | PIM microstructural studies
or squeeze casting. For a variety of and the sintering activity is lower, the percolation threshold. Factors The results of density assessments
reasons, all of these approaches leading to prolonged sintering times influencing the percolation threshold and of compression testing in the
are relatively complex and costly compared to metals. One way to are the particle size distribution, Fe-TCP system are shown in Table2.
and result in a part that has to be influence those parameters is via the particle morphology and relative The relative densities achieved
subsequently machined if a high particle size and, with it, the surface particle sizes of the components. with samples 2, 3 and 4 fall within
degree of shape complexity is energy of the particles. The focus of the reported work the typical range for sintered PIM
required. Also, metals and ceramics may was on the ability to produce a range materials of 95 to 99.5%. In the case
Producing IPCs by PIM processing react chemically during the sintering of metal-ceramic IPCs and the of Fe-TCP-1 with the highest TCP
can potentially offer a number procedure, depending upon the determination of important material volume fraction, however, the density
of advantages; precise control materials used and the sintering properties, particularly the relative is rather low at 90.9 % and this could
of composition, the potential to conditions. Possible reactions must density and the mechanical properties. not be increased by variation of the
influence material properties and therefore be taken into account when A number of different IPC systems sintering parameters. As TCP is
processibility by manipulating particle designing the material and excluded were studied:- a ceramic known to be difficult to
size and morphology and the ability to in order to be able to handle the Iron-tricalcium phosphate sinter, this result is not surprising.
produce parts with a high degree of processing. (Fe-TCP) In general, the compressive
geometrical complexity. In order to achieve an IPC The DV50 particle sizes used for the strength increases and the offset yield
The challenge in PIM processing, structure, both particulate phases two particulate components were strength decreases with increasing
however, lies in the sintering stage must be able to form a continuous 1.65 m and 10.36 m for the iron iron volume fraction. The exception
of the process. Often, the typical network. The minimum volume and beta-tricalcium phosphate to this was Fe-TCP-1, with the
sintering temperatures of ceramics fraction of a component required to respectively. This ICP type is of highest TCP fraction, where the very
are higher than those of metals form a continuous phase is called interest for load-bearing and low compressive strength can be
biodegradable medical implants. attributed to the low density. Fig. 2 Light microscopy and SEM images of polished sections of Fe-TCP
In the micrographs of the sintered composites: (a) Fe-TCP-1, LM (b) Fe-TCP-2, SEM, (c) Fe-TCP-3, LM and (d)
316L stainless steel + silica (SiO2)
Metal Metal Ceramic structures in these Fe-TCP samples Fe-TCP-4, SEM [1]
Composite compo-
Ceramic
fraction fraction The DV50 particle sizes used for
component (Fig. 2), the lighter phase is iron and
nent [vol%] [vol%] these two components were
the darker phase is TCP. The shapes Compressive
Strain at
Bending
4.14m and 2.45 m for the 316L Relative failure
Fe-TCP-1 Iron Ca3(PO4)2 40 60 of the TCP areas are rather angular, Composite strength strength
stainless steel and the silica density [%] (compres-
indicating that the TCP particles [MPa] [MPa]
Fe-TCP-2 Iron Ca3(PO4)2 50 50 sion) [%]
respectively.
have kept their original shape during 316L-Al2O3-1 60/40 94.0 0.5 1003 15.7 31.1 1.0 343 4.6
Fe-TCP-3 Iron Ca3(PO4)2 60 40 316L stainless steel + zirconia sintering. In contrast to this, the iron
(ZrO2) phase fills all accessible voids, except 316L-Al2O3-1 40/60 93.0 1.6 832 16.7 19.0 0.6 116 7.3
Fe-TCP-4 Iron Ca3(PO4)2 70 30
The DV50 value for the stainless in the case of Fe-TCP-1. There is 316L-Al2O3-2 60/40 93.6 0.7 664 15.3 25.6 1.8 251 4.3
316L-Al2O3-1 60/40 316L Al2O3 (76 m) 60 40 steel powder was again 4.14m probably too little iron material in this
and that of the zirconia was 316L-Al2O3-2 40/60 90.8 1.4 205 20.0 1.7 0.4 70 7.3
316L-Al2O3-1 40/60 316L Al2O3 (76 m) 40 60 mixture to fill all voids given by the
0.66m. TCP phase. As TCP does not sinter 316L-Al2O3-3 60/40 93.8 0.3 711 38.1 3.6 0.7 262 15.7
316L-Al2O3-2 60/40 316L Al2O3 (7 m) 60 40
316L stainless steel + alumina properly, the TCP matrix does not
316L-Al2O3-3 40/60 95.8 0.4 1004 65.9 2.6 0.3 244 14.8
316L-Al2O3-2 40/60 316L Al2O3 (7 m) 40 60 (Al2O3) shrink thoroughly during sintering.
The DV50 value for the stainless If there is not enough iron to fill all 316L-SiO2 60/40 95.3 0.1 629 18.0 35.1 1.6 226 3.0
316L-Al2O3-3 60/40 316L Al2O3 (0.8 m) 60 40
steel powder was again 4.14m voids, pores will be left, as can be 316L-SiO2 40/60 98.8 1.2 299 12.5 4.4 0.4 98 16.0
316L-Al2O3-3 40/60 316L Al2O3 (0.8 m) 40 60 seen in Fig. 2 (a). This observation
and, for this system, three
also correlates with the low relative 316L-ZrO2 60/40 97.1 0.5 1893 78.2 14.8 2.1 821*
316L-SiO2 60/40 316L SiO2 60 40 different DV50 values were studied
for the alumina 75.57 m, density measured for Fe-TCP-1 and 316L-ZrO2 40/60 96.1 0.7 1869 52.0 5.6 0.4 565 31.2
316L-SiO2 40/60 316L SiO2 40 60
7.02m and 0.77 m. These three its poor mechanical performance. The
316L-ZrO2 60/40 316L ZrO2 60 40 results of the density assessments Table 3 Densities and mechanical test results for the 316L-ceramic
different alumina particle sizes
and of compression testing of the composites [1]
316L-ZrO2 40/60 316L ZrO2 40 60 were used to study the influences
on percolation and mechanical 316L-ceramic composites are given
Table 1 Compositions of the metal-ceramic IPCs processed by PIM [1] properties. in Table 3. Both 316L-ZrO2 composites show order of 2000 MPa and the bending
For the 316L-SiO2 system, very high compressive strength and strength is around 900-1200 MPa, the
Relative Compressive Offset yield The compositions of the various 316L-SiO2 60/40 shows relatively low high relative density. Furthermore, 316L-ZrO2 60/40 is cited as a good
strength Strain at
Composite strength batches of IPCs processed by PIM compressive strength but the highest the bending strength values exceed example of how ceramic and metallic
density [%] failure [%]
[MPa] (Rp0.2) [MPa]
are shown in Table 1. After moulding strain at failure. Despite having the those of all of the other materials. properties can be combined.
Fe-TCP-1 90.9 0.3 224 22.1 187 25,1 6.5 0.9 and debinding, all of the composite highest observed relative density of The strain at failure of the metal-rich In the studies of the 316L-Al2O3
materials were sintered in an argon all investigated composites, 316L-SiO2 316L-ZrO2 composite is the lowest system, the alumina particle size was
Fe-TCP-2 94.7 1.1 917 9.2 686 37,6 7.9 0.6
atmosphere. In the case of the Fe-TCP 40/60 shows rather poor mechanical of all 316L-ceramic composites with shown to have a large influence on
Fe-TCP-3 97.2 0.3 987 7.2 533 6,4 14.3 0.7 composites, the maximum sintering performance. At this point, this 60 volume% of metal, but is still the microstructure and mechanical
Fe-TCP-4 98.3 1.0 1036 19.6 468 30.6 22.4 0.8 temperature was chosen as 1270C, relatively poor mechanical strength in high compared to a pure ceramic. performance. When combining small
while the 316L-based composites the 316L-SiO2 system remains to be As the compressive strength of ZrO2 316L particles with relatively large
Table 2 Densities and compression test results for the Fe-TCP composites [1] were sintered at 1350C. explained. stabilised with 3 % Y2O3 is of the alumina particles, the IPC structure
PIM microstructural studies | contents page | news | events | advertisers index | | contents page | news | events | advertisers index | PIM microstructural studies
with zirconia showed strength values

close to those of pure zirconia, but the
material could be strained far more
than a pure ceramic would allow.
As well as creating materials with
promising mechanical properties,
metal-ceramic IPCs offer the possi-
bility of being combined with either
pure material (metal or ceramic) in
a two-component injection moulding
process (Fig. 3, left). In this case,
there is the opportunity for positive
joining of the pure material and the
composite. As the surface of the
composite contains both metal and
ceramic areas, these areas can come
Fig. 3 Two-component (left) and three-component (right) parts in the system into contact with the pure material
316L-ZrO2 [1] and form a stable bond during
sintering. It is even possible to use Fig. 4 Micrographs of as-polished Charpy bar cross-sections for samples sintered at (a) 1280C and (b) 1300C [2]
did not form, as the ceramic particles 316L during sintering, which filled the the composite as a form of bonding
did not percolate entirely and tended voids between the ceramic particles. material between the pure metal
towards segregation during injection This effect was also observed for and the pure ceramic. The author A microstructural evaluation of max Si, 0.25% max C, 0.045% max the criticality of carbon control,
moulding. In composites with ceramic 316L-zirconia composites, which demonstrated this by producing Metal Injection Moulded HK-30 P, 0.03% max S). The alloy design one objective of the study was to
particles smaller than the 316L or exhibited the highest values for three-component PIM parts in the A presentation by Keith Murray, includes a niobium addition to give evaluate the benefits of low-oxygen
comparable in size, the IPC structure compressive and bending strength material system 316L-ZrO2 with the Andrew Coleman, Martin Kearns a fine dispersion of stable carbides gas atomised powders in controlling
did form at the same composition of all the composite materials composite in the middle (see Fig. 3, and Toby Tingskog (Sandvik Osprey for strengthening purposes and a chemistry and therefore finished part
due to the better material flow of investigated. The 316L-rich composite right). Ltd., United Kingdom) and Viacheslav silicon addition to increase resist- properties.
Ryabinin and Erainy Gonzalez (TCK ance to carburisation. Three heats of pre-alloyed HK-30
SA, Dominican Republic) reported on Control of both carbon content based powders were produced using
Element (wt%) Fe Cr Ni Nb Mn Si Mo N C P S O a microstructural evaluation of MIM and distribution in the sintered Sandvik Ospreys proprietary inert
HK-30 stainless steel. components is critical in controlling gas atomisation process employing
HK-30A Bal 25.4 19.8 1.31 1.19 1.29 0.16 0.30 0.025 0.004
In recent years, the production final grain size and properties. nitrogen gas. The powders were
HK-30B Bal 24.9 19.9 1.33 1.21 1.44 0.08 0.15 0.32 0.019 0.004 0.066 of a variety of high temperature Consequently it is essential that then processed to particle size
turbocharger components by MIM the relationship between powder distributions of 90%-22 m and
HK-30C Bal 25.3 20.0 1.32 1.16 1.47 0.16 0.16 0.33 0.020 0.004 0.077
has successfully displaced precision characteristics, including chemistry, 80%-22 m by air classification. The
Table 4 Chemical compositions of the HK-30 powders used in the study [2] casting and machining processes. and MIM processing parameters chemical compositions of the batches
The operating environment in modern are well understood so that these are shown in Table 4. The A suffix
diesel engines demands very good requirements can be achieved. denotes the standard HK-30 composi-
Sinter
Particle UTS 0.2%YS Density, Density Hardness Carbon Change high temperature wear and corrosion The objective of the reported tion, while the alloys with suffixes B
Alloy Temp %El
Size (m) (MPa) (MPa) (g/cm3) (%TD) (VHN) (%) in %C
(oC) resistance coupled with excellent study was to investigate the effect and C represent alloys doped with
1280 822 456 11.0 7.41 95.21 237 0.27 fatigue properties. of powder particle size distribution increasing additions of additives
90%-22 A modified 310 stainless steel and powder chemistry and sintering designed to control grain size.
1300 857 452 10.0 7.74 99.46 249 0.27
HK-30A -0.03 known as HK-30 is used extensively conditions on MIM component Feedstocks, based on these
1280 830 459 11.5 7.38 94.74 225 0.27 for this type of application (standard densities and metallurgical powder batches, were moulded
80%-22 310 composition: Fe: Bal, 24-26% properties with a particular focus on and debound and then sintered in a
1300 830 443 10.3 7.72 99.10 246 0.27
Cr, 19-22%Ni, 2% max Mn, 1.5% grain size and density. Recognising nitrogen atmosphere at either1280C
1280 590 371 2.0 7.55 97.41 181 0.28
90%-22
1300 888 506 9.7 7.72 99.66 263 0.30
HK-30B -0.03 Sintering HK-30A HK-30A HK-30B HK-30B HK-30C HK-30C
1280 527 335 2.3 7.64 97.90 155 0.29
temp (C) 80%-22 90%-22 80%-22 90%-22 80%-22 90%-22
80%-22
1300 865 495 9.5 7.71 98.77 259 0.30
1280 7-8 7-8 N/A 11-12 N/A 11
1280 756 441 8.3 7.22 92.52 211 0.31
90%-22 1300 N/A 5-6 N/A 8-9 N/A 8
1300 868 507 6.9 7.70 98.74 268 0.32
HK-30C -0.02 not possible to not possible to not possible to
1280 605 369 2.0 7.50 96.63 196 0.30 more even than also smaller very fine grain
Comment decide because decide because decide because
80%-22 90%-22 grains size
1300 862 495 7.7 7.67 98.85 263 0.33 of precipitations of precipitations of precipitations
Table 5 Mechanical property data for as-sintered tensile bars [2] Table 6 ASTM grain size assessments for the as-sintered tensile bars [2]
PIM microstructural studies | contents page | news | events | advertisers index | | contents page | news | events | advertisers index | Green machining of MIM parts
a b
Low volume and prototype
MIM components using green
machining and sinter joining
The rapid production of small quantities of Metal Injection Moulded (MIM)

components is of increasing interest to producers worldwide as they
Fig. 5 Mechanical properties of HK-30 variants sintered at (a) 1280C (left) and (b) 1300C (right) [2]
look to provide customers with prototypes that offer similar properties to
high volume MIM components. In this study Shinya Sakurai and Kazuaki
or 1300C, these temperatures being refiner appears, in B samples, to enhances both strength levels and Nishiyabu (Kinki University, Osaka, Japan) and Shigeo Tanaka (Taisei Kogyo
within the sintering window predicted have caused a significant reduction hardness. These enhanced properties
by Thermocalc. Table 5 presents the in strength and ductility, despite should result in performance
Co. Ltd., Osaka, Japan) report on the development of a novel MIM process
results of assessments of as-sintered an increase in density. However, a improvements of turbocharger vanes involving the sinter-joining of components produced by the machining of
tensile properties, hardness and further increase in grain refiners in green MIM compacts. The study focuses in particular on achievable shape
carbon content. These data show that C samples has resulted in strength Author and dimensional control.
carbon content was well controlled values, which approach standard
in all cases, with a consistent loss of HK-30, but again with lower density. Dr David Whittaker is a consultant to
0.02-0.03% compared to the starting These trends are shown in Fig. 5 a. the Powder Metallurgy and associated
powder. This was anticipated in view Sintering at 1300C resulted in industries.
of the low and consistent oxygen much higher sintered densities. The Tel: +44 1902 338498
contents in the starting powders. increased density drives towards Email: whittakerd4@gmail.com
It was also demonstrated that higher strength and ductility, A perceived limitation in the Various methods have been techniques such as nano-imprinting
increasing the sintering temperature although the coarsening effect References conventional Metal Injection Moulding proposed to tackle these issues or LIGA.
from 1280 to 1300C had a significant moderates the observed increases to (MIM) processing of complex shaped by introducing a sophisticated Additionally, during the
effect on sintered density. All alloy and some extent (Fig. 5 b). [1] Sebastian Hein et al., Powder parts with internal or external polymer-based lost form technology development phase of MIM
particle size combinations achieved The overall conclusion from Injection Moulding of Metal-Ceramic undercuts rests in the fact that fragile into the MIM process. The validity products, short delivery lead-times
near to full density at 1300C. the reported study was that the Interpenetrating Phase Composites, green compacts are not easy to eject and usefulness of one variant of this and low costs are required for the
Metallographic assessments addition of a small amount of as presented at the Euro PM2014 from the mould. As a result, these advanced technology, the sacrificial manufacturing of prototype MIM
were carried on samples from each grain refiner to pre-alloyed HK-30 Congress, Salzburg, Austria moulds are therefore manufactured plastic mould inserted MIM (SPiMIM) parts. Rapid prototyping by metal
sintering run and powder type. stainless steel powder is effective by the precision machining and process, has been demonstrated. Additive Manufacturing is one of
Images of the polished microstruc- in achieving grain refinement [2] Keith Murray et al., A Microstruc- assembly of several tooling parts However, this is a costly method the useful candidate methods for
tures for selected variants are shown without sacrificing densification or tural Evaluation of Metal Injection to incorporate sliding cores for the as it is necessary to prepare the the visualisation of the shape of
in Fig. 4. Carbide levels appeared to mechanical properties on sintering Moulded HK-30, as presented at the removal of the undercut parts. These plastic moulds or forms by methods products for customers. However, 3D
be evenly distributed in all samples, in a nitrogen atmosphere at a Euro PM2014 Congress, Salzburg, issues increase both the cost of the including machining, injection printed parts differ substantially from
with the carbide size reflecting the temperature of 1300C. The addition Austria mould and the complexity of the moulding or rapid prototyping of MIM parts in terms of dimensional
grain size. was also effective in reducing some required moulding machine. plastics or semiconductor fabrication tolerances, surface roughness and
ASTM grain sizes were evaluated of the distortions that occur at high
(Table 6), although not all samples temperature.
could be easily evaluated. These data It was further concluded that
confirmed that the addition of grain gas atomised HK-30 powders are
refiners did modify the grain size and ideally suited to the production of
that higher sintering temperatures high performance turbocharger
resulted in coarser grain sizes, with a components to close tolerances with
typical reduction of 2-3 ASTM units. excellent control of carbon leading to
The tensile properties for A uniform shrinkage and predictable
samples sintered at 1280C exhibit properties. By proprietary
good tensile strength and ductility, modification of the base alloy, it is
despite their relatively low densities. also possible to achieve significant
The increasing addition of grain grain refinement, which in turn Fig. 1 Incorporation of green machining and sinter joining in the MIM process
Green machining of MIM parts | contents page | news | events | advertisers index | | contents page | news | events | advertisers index | Green machining of MIM parts
Fig. 2 Shapes of as-moulded or machined green compact and sintered part Fig. 4 Tool paths for green machining
shape in a machining centre. kneaded with a constant solids by the machining procedure shown
Depending on the required shape or loading of 66 vol%. Using this in Fig. 3, using the machining
material combination, multiple green feedstock, a block-shaped green conditions listed in Table 1. Also, the
compacts are assembled. Finally, MIM compact, as shown in Fig. 2(a), tool paths used for green machining
the assembly of machined green was moulded using a small injection are shown in Fig. 4. The green
compacts is debound and sintered to moulding machine. The density of the compacts were debound at 600C
obtain the final sintered part. green compact was 5 mg/mm3. for 2 h in a nitrogen atmosphere
and sintered at 1250C for 2 h in an
Material and specimen geometry Fabrication conditions argon atmosphere, using a combined
used The shapes and dimensions of vacuum debinding and sintering
The metal powder used in the the machined green compact and furnace.
reported study was a 410L stainless sintered part are shown in Fig.2(b)
Fig. 3 Green machining procedure
steel water atomised powder. The and (c). The net-shaped green Evaluation method
binder used comprised poly-acetyl compact was prepared from the The optical measurement system
mechanical properties. In preparation emerges as a potentially useful dimensional control achievable in the polymer and paraffin wax and was block-shaped green MIM compact used was a commercial 3D digital
for mass production, MIM processing method for rapid trial production of green machined compacts and the
parameters such as material metallic parts. The machined green final sintered parts in this process.
selection, debinding conditions compacts are then assembled and
and sintering shrinkage, and the joined into complex component Experimental details
mechanical properties of the final assemblies during sintering. This type
MIM parts, need to be defined at an of rapid prototyping MIM technology Manufacturing method
early stage. can provide sample metallic products The complex-shaped sintered part
There have been recent advances in with short lead-times and lower cost was manufactured by incorporating
fine and complex-shaped machining, and also has the potential to proceed green machining and sinter joining
such as five-axis numerical successfully to mass production by in the MIM process as shown in
control, high-speed spindles and MIM. The process can also be adopted Fig.1. The process is divided into
high- performance cutting tools, for insert injection moulding or three steps. Firstly, the block-shaped
Fig. 5 Micrographs showing the surface condition of machined green compact and sintered part
and therefore the machining of the 2-component injection moulding. green compact is injection moulded.
green MIM compacts followed by This report concentrates in Secondly, the as-moulded green
a debinding and sintering process particular on defining the shape and compact is machined to near-net Machined green compacts Sintered parts Measuring positions
CAD Measure Dif. CAD Measure Dif.
X1 14.89 14.90 +0.01 X1 13.00 13.00 0.00
Type of Cutting Corner Effective Spindle
No. of Feed rate Side step Down step Y1 8.02 8.01 -0.01 Y1 7.00 7.13 +0.13
milling diameter radius length speed
tool (mm/min) (mm) (mm)
cutter (mm) (mm) (mm) (min-1) X2 1.26 12.6 0.00 X2 1.10 1.08 -0.02
(i) End 1.0 0 4 25,000 600 0.600 0.055 Y2 1.78 1.78 0.00 Y2 1.55 1.54 -0.01
(ii) End 0.6 0 4 25,000 75 0.025 0.030 D1 0.99 0.97 -0.02 D1 0.86 0.85 -0.01
(iii) End 4.0 0 12 8,000 1,100 2.400 0.120 D2 0.76 0.75 -0.01 D2 0.66 0.66 0.00
(iv) Ball nose 1.0 0.1 8 14,500 131 0.250 0.050 D3 0.99 0.97 -0.02 D3 0.86 0.85 -0.01
(v) Ball nose 2.0 0.1 8 11,100 1,075 0.600 0.080 D4 0.76 0.74 -0.02 D4 0.66 0.66 0.00
Table 1 Conditions of green machining Table 2 Differences in dimensions of machined green compacts and sintered parts
Green machining of MIM parts | contents page | news | events | advertisers index | | contents page | news | events | advertisers index | Green machining of MIM parts
Fig. 6 Differences in shape of machined green compact and sintered part, compared with the CAD data Fig. 8 Differences in shape of joined and single-piece sintered parts, compared with the CAD data
Z1 Z2 Z3 Z4 Z5 X1 X2 X3 X4 Z1 Z2 Z3 Z4 Z5 X1 X2 X3 X4
(a) Machined (a) Joined sintered
-0.001 -0.001 +0.004 0.000 0.000 +0.004 -0.006 -0.002 -0.004 +0.029 +0.055 +0.003 +0.025 -0.014 +0.088 -0.097 -0.017 +0.016
green compact parts
(b) Sintered part +0.021 +0.029 -0.064 +0.014 +0.030 -0.048 +0.023 -0.004 +0.005 (b) Unit sintered
+0.021 +0.029 -0.064 +0.014 +0.030 -0.048 +0.023 -0.004 +0.005
parts
Table 3 Differences in position of machined green compact and sintered part to CAD data
Table 4 Differences in position of joined and single-piece sintered parts to CAD data
machined separately in preparation lower than that of the single-piece

for sinter joining, compared with the part, 90.4. This is because the square
CAD data. These two green compacts column became inclined during
are assembled as shown in Fig. 7(c). the sintering of the two assembled
In the machined green base plate, machined green compacts. On the
the significantly positive differences other hand, on sintering of single
in dimension are seen at the bottom piece green compacts, the corners
corner of quadrilateral hole and four are formed virtually at right angles
square bases. The machined green and are retained symmetrically.
square column also has positive
differences in dimensions at the Conclusions
internal corners. The authors have
concluded that further improvement On the basis of the shape
in machining accuracy is required. measurements derived from the 3D
Fig. 7 Differences in shape, compared with the CAD data, of two separate machined green compacts and the component Fig. 9 Corner angles of joined and
The effects of sinter joining are digitiser, the authors concluded that
assembly method single-piece sintered parts
shown in Fig. 8, which compares the the green compacts were machined
differences in shape of parts made in close precision to the CAD data,
image scanning instrument. The of machined green compacts. The sufficient degree. by assembly and sinter joining and while dimensional change in sintering Contact
principle of this full-field surface authors attribute this mainly to the Fig. 6 shows the differences in those processed by MIM as a single shrinkage was controlled to within a
measurement system is based on an shrinkage in sintering. shape of the machined green compact piece. The differences in position of few tenths of a micron. Prof Kazuaki Nishiyabu and Shinya
optical triangulation method. and sintered part compared with the the parts made by these two process Sintered joining could be Sakurai
Dimensional comparisons CAD data. The differences in position variants to the CAD data are also accomplished without significant Kinki University
Results Table 2 shows the CAD data and are listed in Table 3. Negligible shown in Table 4. With the joined defects, but it is suggested that the 3-4-1 Kowakae, Higashiosaka
dimensions measured at several differences in shape are seen in the sintered part, a significant difference sintering method of the joined green Osaka 577-8502, Japan
Surface condition positions on both the machined green machined green compacts. In the in shape compared with the CAD data compacts should be developed for
Fig. 5 shows micrographs of the compacts and sintered parts. The case of the sintered parts, the flat is seen at the top portion (X2) of the greater accuracy. Dr Shigeo Tanaka
surfaces of machined green compacts deviations in dimension between the portions (Z2, Z4) of the bottom plate square column and greater distortion Overall, it was concluded President
and sintered parts. The cutter marks CAD data and the measurements are slightly higher, but the tip of the is observed on the base plate, apart that convincing evidence has Taisei Kogyo Co., Ltd,
are visible on the surface of machined were within 0.02 mm except in the square column (Z3) and the side from around the square column. been provided that the proposed 26-1 Ikeda-kita, Neyagawa, Osaka
green compacts, but they are not case of the width of the sintered part, edges of the bottom plate are lower. Fig. 9 shows the corner angles of manufacturing method is potentially 572-0073, Japan
visible on the sintered parts. It was Y1. It was therefore concluded that Fig. 7(a) and (b) show the joined and single-piece parts. The useful for the production, with shorter www.taisei-kogyo.com
observed that the surface roughness the green machining can guarantee differences in shape of the green corner angles of the joined sintered lead-times and lower costs, of many
of sintered parts was larger than that the dimensional tolerance to a base plate and squared column, part are 89.4 and 88.2, which is types of small-lot MIM parts.
PM CHINA 2015
Events / Advertisers | contents page | news | events | advertisers index |
Events Guide Advertisers Index April 27-29 2015

ARCMIM 2
Shanghai Everbright Convention & Exhibition Centre
2015 Advanced Materials Technologies Pte Ltd 26
Advanced Metalworking Practices, LLC 14
PM China 2015 Expo Arburg GmbH & Co. KG OBC
April 27-29, Shanghai, China
www.cn-pmexpo.com/en/
Ametek Specialty Metal Products
AMPM Conference
24
67
Chinas largest PM & MIM exhibition
PowderMet2015 AP&C Advanced Powders & Coatings 53
May 1720, San Diego, CA, USA Atect 25
www.powdermet2015.org
AT&M 20
AMPM Additive Manufacturing with PM Carbolite-Gero 11
(co-located with PowderMet2015) Carpenter Powder Products 13
May 1719, San Diego, CA, USA
www.ampm2015.org Centorr Vacuum Industries, Inc 12
Ceramitec 2015 49
Rapid 2015 CM Furnaces, Inc 27
May 19-21, Long Beach, California, USA
Cremer Thermoprozessanlagen GmbH 33
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www.europm2015.com
FCT Anlagenbau GmbH 30
Ceramitec 2015 Formatec Ceramics 29
October 20-23, Munich, Germany Greenlong (Qingdao Greenlong Machinery Co Ltd) 16
www.ceramitec.de
Indo-US MIM Tec 4
APMA 2015 3rd International Conference on Powder Jiangxi Yuean Superfine Metal Co Ltd 18
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PM China 2015 IBC
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80 Powder Injection Moulding International March 2015 2015 Inovar Communications Ltd Vol. 9 No. 1
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Vol. 9 No.

Managing Director and Editor

Clear enthusiasm for MIM

amongst product designers

Complex precision components.

Partners Group acquired Dynacast from exiting finan-MY

& Company, an existing shareholder, and the companys

that Partners Group and Kenner & Company will work

Automatic Cleaning Features of binder

ColdFinger Debind Trap forced flow

Gas Tight Retort Design Superior gas control

Laminar Gas Flow efficient and effective gas

Simple Ease of Use PLC controls via Excel

EPSON ATMIX CORPORATION

Low Alloy Steel

Carbolite and Gero announce merger showcase the companys range of

Q2 results times but also the evasion of multiple processes usually

MIM debind and sinter wide materials portfolio including

Indias Defence Minister introduced to

HIGH QUALITY On the leading edge of

ISO 9001:2008 Certified www.amp-llc.net

Sandvik Osprey Limited

GREENLONG Vacuum furnace manufacturer TAV

New powder alloy is as light as

Metal Additive Manufacturing: A new

Vol. 1 No. 1 SPRING 2015

from the www.

Jiangxi Yuean Superfine Metal Co., Ltd YUELONG GmbH US Distributor

Simulation of powder/binder separation part rejection is powder-binder

SIMTech focuses on PIM of dissimilar KIT develops industrial scale PIM

Our services focus on product development and

eMBe Products & Service GmbH

based headphone manufacturer retail for around $200, audiophile

Step up to the world class quality Aluminum Nitride heat sink

error of 0.191 mm. The reason was

CM Furnaces, long recognized as an industrial leader in performance-proven, high

The challenge of carbon control has strongly influenced the development

FCT Anlagenbau GmbH

FCT Anlagenbau GmbH

excellent magnetic properties leading product assessment (size, density,

printer applications. residual carbon is required, such as

roller furnaces MIM automotive component produc-

reduction occurs during sintering more thermodynamically stable

carburisation and decarburisation Fe3C (s) + H2O (g) 3 Fe (s)

MIM at GKN Sinter Metals:

moulding of thermosetting plastics MIM technology in Bad

materials accounting for similar

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Advances in the Metal

tried to avoid this by using an elastic Beta-titanium alloys based on Ti-Nb

deformability. Further studies are planned. Ti

Ti-6Al-4V and Ti/ZrO2 composites

application, meaning either in contact particles was presented by Neves et

(<25m). As a result of the process

particle size smaller 45 m was mixed

Image courtesy of Euro PM2014-wildbild

and M Dahms (University of Applied

with Powder Metallurgy

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