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Te Metal Injection Molding (MIM) Process :: Total Materia Article
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Te Metal Injection Molding (MIM) Process
Te Metal Injection Molding process is characterized by high pressure injection of powdered metals and binders rather than te conventional gravity fed processes.
Te main applications for this technique are to produce small and often more complex parts often ranging in weight from 0.5 to 150g.
Metal Injection Molding (MIM) is a powder metallurgy process. Te difference between MIM and conventional powder metallurgy is that in MIM, metal powder along with binders is injected under high pressure into te die or mold cavity instead of flowing by gravity.
Te metal powder used for this is finer than conventional powder with particle sizes typically of 20 µm in diameter being used. Generally, te powder mix contains a much higher percentage of binders and flow agents. Wherein, binders generally include various waxes and thermoplastics. Te compounded material is injected with conventional plastic injection molding machines (slightly modified) into metal dies normally having one to eight cavities.
Te molded component is called te green part. Te binders are first driven off either by heating, by solvent extraction, or by a combination of both methods and approximately 80% of te binders are removed. Debinding time is directly related to wall thickness. After debinding, te part is called te brown part which is porous and fragile but size remains te same as at te time of molding. Te brown parts are then sintered as done in conventional powder metallurgy.
This is carried out in a vacuum or inert-atmosphere furnace at a temperature of approximately 1300°C depending on te material used for processing. However, sintering temperatures are generally well below te melting point of te material. Te entire cycle including debinding normally takes about 24 to 36 hours.
Typical characteristics and applications of metal injection-molded parts
As mentioned above, typical metal injection-molded parts are small and complex in nature. Te process is more advantageous for more complex parts. In this process, high precision is possible to achieve. This method eliminates te constraint imposed by conventional powder metallurgy methods i.e. te side wall should be parallel. Very small size parts i.e. smaller than a golf ball in volume, weigh in te range of 0.5 to 150 g, and a wall thickness of less than 6.3 mm can be achieved using this method. It is possible to produce multi-functional parts with thin walls, sharp corners, undercuts, cross holes, screw threads, contours, gear segments, and similar features without secondary operations.
Te densities of parts produced through this process are normally greater than those of conventional powder metallurgy parts, ranging between 95 and 99 % of theoretical maximum density.
Figure 1: Te MIM process
Figure 2: Molding machine in a MIM Shop
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