WO1997038811A1 - Procedes de moulage par injection, en particulier procedes de moulage de metaux par injection - Google Patents

Procedes de moulage par injection, en particulier procedes de moulage de metaux par injection Download PDF

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Publication number
WO1997038811A1
WO1997038811A1 PCT/GB1997/001015 GB9701015W WO9738811A1 WO 1997038811 A1 WO1997038811 A1 WO 1997038811A1 GB 9701015 W GB9701015 W GB 9701015W WO 9738811 A1 WO9738811 A1 WO 9738811A1
Authority
WO
WIPO (PCT)
Prior art keywords
mix
binder
mixes
compact
mould
Prior art date
Application number
PCT/GB1997/001015
Other languages
English (en)
Inventor
David John Stephenson
Jeffrey Robert Alcock
Original Assignee
Apv Uk Plc
Cranfield University
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Apv Uk Plc, Cranfield University filed Critical Apv Uk Plc
Publication of WO1997038811A1 publication Critical patent/WO1997038811A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B22F1/103—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/24—Producing shaped prefabricated articles from the material by injection moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
    • B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • This invention relates to injection moulding processes and particularly, but not exclusively, to metal injection moulding processes.
  • Metal injection moulding is a technique which can be used for the mass production of intricately-shaped metallic components.
  • Metal powder is mixed with a binder comprising a polymer, and the mixture is heated and forced to fill a mould cavity.
  • the moulded compact is debound and then sintered to the required density. Though the compact shrinks, the original shape of the mould is retained in the final component, even when the mould shape is complex.
  • Polymer co-injection moulding is a process for producing polymer sandwiches using a twin-barrelled injection system.
  • Stage 1 - material from barrel A is injected into a mould to form the skin of the compact.
  • Stage 2 - a selector valve is repositioned to allow injection of the core material from barrel B whilst shutting-off barrel A. This forces the skin material to the outer parts of the mould cavity.
  • Stage 3 - the valve is re-set to A for a short shot of material from barrel A to complete the skin at the injection point.
  • the mould is then packed under pressure.
  • a second method of operating the polymer co-injection moulding process is as follows: 1) Injection of material from barrel A to constitute the skin,
  • a method of producing a sintered component comprises moulding a compact which incorporates a binder, substantially removing the binder from the compact, and sintering the resulting debound compact, in which the compact is produced by an injection moulding process from at least two different mixes, each mix comprising a binder and a powdered filler material, the filler material being a metal and/or ceramic material, a first of said mixes being injected into a mould to incompletely fill the mould, followed by injection of a second of said mixes, the arrangement being such that said first mix forms an outer layer of the compact and said second mix forms an inner layer of the compact.
  • a suitable ceramic filler material may comprise calcined alumina.
  • the particle size is preferably less than 20 microns.
  • the binder may comprise a polymer or a wax. If a polymer, the binder may be in liquid form.
  • the step of injecting the second mix may be accompanied by simultaneous injection of the first mix as a co-axial stream, with the first mix encircling the second mix in said stream.
  • the step of injecting the second mix into the mould is preferably followed by injection of some more of the first mix into the mould so as to provide a complete skin of material formed from the first mix.
  • the material with the finer particle size would sinter first and a method of retarding the sintering of the finer particles, or/and increasing the rate of that of the coarser particles would be required.
  • Retardation of the sintering rate can be achieved by either adding a second non-sintering phase or decreasing the green density.
  • the mechanical keying of the faster sintering material to the slower one is known to reduce densification, so there will also be some 'built-in' tendency to equalise the densification rates. Acceleration of the sintering rate could be achieved by the use of dopants, liquid phase sintering etc.
  • filler powder of one of the mixes is finer than the filler powder of the other mix, it can sometimes be preferable to employ a lower volume percentage of filler powder in said one mix than in the other mix, when this assists in achieving comparable sintering rates.
  • the ratio of the volume percentages of the filler powder in the mix having coarser filler powder to that in the mix having finer filler powder is in the range 1.25. to 1.50 and is most preferably in the range 1.30 to 1.45.
  • the invention also comprises a sintered compact produced by the inventive method.
  • Figure 1 shows measurements of the apparent viscosity of powder-binder feed-stocks and polypropylene in accordance with the invention
  • Figure 2a is a copy of a scanning electron microscope image of a co- injected metal compact, thermally debound and pre-sintered to 850°C (2 hrs) in hydrogen, in accordance with the invention
  • Figure 2b is a similar microscope image of a co-injected metal compact, sintered to 1300°C (4 hrs) in vacuum, in accordance with the invention, and Figure 3 illustrates a suitable injection moulding machine.
  • the binder system a combination of carnuba and paraffin wax, Stearic acid and polypropylene, was adapted from Wiech.
  • the properties of the constituents are given in Table II.
  • the waxes impart low viscosity to the binder-powder mix and the carnuba wax also acts as a lubricant and mould release agent.
  • the waxes are soluble in organic solvents and so may be removed prior to thermal debinding.
  • Stearic acid aids dispersion of the powder and also improves powder- polymer adhesion.
  • the high molecular weight polypropylene functions as a backbone polymer, imparting green strength to the polymer-metal compact.
  • the range of melt and degradation temperatures of the polymer and waxes produces a more uniform debinding rate during subsequent thermal debinding.
  • Table III shows the composition of the feed-stocks produced for injection moulding of core and skin of the compact.
  • the weight ratio of binder constituents was constant for core and skin.
  • the volume fraction of powder in the core was held at 12.5% less than in the skin, to prevent delamination adjacent to the core-skin interface caused by the higher sintering rate of the finer particle size iron powder.
  • Feed-stocks were initially blended in a shaker-mixer for 30 minutes at room temperature. Each was subsequently compounded in a twin-screw co- rotating extruder, at a screw speed of 300 rpm and temperature of 200°C. The resulting feed-stock was granulated.
  • the apparent viscosity of the polymer-binder mixes was measured at 200°C, using a capillary rheometer of die length 2 cm and capillary radius 0.5 mm. The shear rate was varied between 533 and 12000s "1 . The results are shown in Figure 1.
  • the apparent viscosity of the stainless-steel powder-binder mix was greater than that of the iron powder-binder mix, owing to the higher powder loading. Studies indicate that in polymer co- injected systems, this is a requirement to prevent break through of core material to the skin of the compact.
  • the high wax content of the binder system produces apparent viscosities for both the metal powder-polymer systems which are similar to that of pure polypropylene.
  • Disks of diameter 76 mm and thickness 3 mm were injection moulded on a 30-ton, twin-barrelled injection moulding machine. Moulding conditions are given in Table IV. Compacts were sectioned for debinding and sintering.
  • Figure 3 illustrates a suitable injection moulding machine.
  • Shot size (mm) Al 30 - 55 12 -37
  • R ramp rate
  • T temperature
  • D dwell time
  • Figure 2b shows a sintered compact. No delamination is visible at the skin-core interface.
  • the dark contrast particulates in the skin are alumina.
  • the core shows some porosity of size less than 10 ⁇ m.
  • the density of the sintered compacts measured by a liquid immersion method was 90%.
  • Two ceramic materials may be co-injected, preferably two different particle sizes of alumina.
  • Ceramic powder size 0.5 ⁇ m (skin) and 1.0 m (core). 2)
  • the binder systems vary from some of those used previously, notably in the use of polyethylene and high wax and high Stearic acid content in some mixes.
  • the injection moulding temperature used is much less for these systems, being 140° to 180°C for the LMWPP based systems and 90° to 120°C for binder system A, which contains no backbone polymer.
  • Figure 3 illustrates an injection moulding machine 10 with twin barrels, namely 1 1 and 12, and a control valve 13, through which moulding materials A (barrel 1 1 ) and B (barrel 12) are discharged to a mould 14, by way of a passageway 15.
  • the mould 14 is provided with cooling/temperature control ducts 16.
  • Sequential injection comprises use of material A, followed by B, followed by A.
  • Simultaneous moulding comprises use of material A, followed by A plus B, followed by A.
  • a suitable filler comprises calcined alumina, with a preferred particle size of less than 20 microns.
  • the invention can be used to produce a component having a skin of ceramic or ceramic-based material and a core of metal or metal-based material, or vice versa.
  • MCM metal co-injection moulding
  • a wax may be used as a binder material.
  • a non-powder that is, a liquid binder material, may be employed.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne un procédé de production d'un composant fritté, qui consiste à mouler un aggloméré contenant un liant, à éliminer sensiblement le liant de l'aggloméré et à fritter l'aggloméré résultant qui n'est plus lié. L'aggloméré est produit grâce à un procédé de moulage par injection qui utilise au moins deux mélanges (A, B) différents, chaque mélange comprenant un liant, de préférence sous forme de poudre, et un matériau de charge en poudre. Le liant comprend un matériau à base de polymère. Le matériau de charge comprend un métal et/ou un matériau de charge céramique. Les mélanges sont injectés soit séquentiellement soit simultanément dans un moule (14), de façon que le premier mélange forme une couche extérieure de l'aggloméré et que le second mélange forme une couche intérieure de l'aggloméré.
PCT/GB1997/001015 1996-04-13 1997-04-11 Procedes de moulage par injection, en particulier procedes de moulage de metaux par injection WO1997038811A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9607718.5 1996-04-13
GBGB9607718.5A GB9607718D0 (en) 1996-04-13 1996-04-13 Injection moulding processes especially metal imjection moulding processed

Publications (1)

Publication Number Publication Date
WO1997038811A1 true WO1997038811A1 (fr) 1997-10-23

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999021709A2 (fr) * 1997-10-29 1999-05-06 Koninklijke Philips Electronics N.V. Procede de production d'un composant electronique multicouche
WO2000076697A2 (fr) * 1999-06-15 2000-12-21 Honeywell International Inc. Co-frittage de materiaux similaires
WO2001000378A1 (fr) * 1999-06-23 2001-01-04 Robert Bosch Gmbh Element chauffant a pointe ceramique avec contacts integres et procede permettant de produire cet element
EP1570804A1 (fr) * 2004-03-05 2005-09-07 Straumann Holding AG Objet dentaire et méthode de manufacture via moulage par injection
DE102011102456A1 (de) * 2011-05-25 2012-11-29 Karlsruher Institut für Technologie Bindemittelsystem für thermoplastische Formmassen für Niederdruckspritzguss
DE102013221011A1 (de) * 2013-10-16 2015-04-16 Bayerische Motoren Werke Aktiengesellschaft Verfahren zur Herstellung eines keramischen Formteils, Verwendung von sekundärer Oxidkeramik und Spritzgussvorrichtung zur Herstellung eines keramischen Formteils
CN115502391A (zh) * 2022-09-15 2022-12-23 浙江省冶金研究院有限公司 一种表面陶瓷硬化粉末高速钢的制备方法

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0115104A1 (fr) * 1983-01-24 1984-08-08 Sumitomo Chemical Company, Limited Préparation de corps minéraux frittés
WO1990009461A2 (fr) * 1989-02-15 1990-08-23 Technical Ceramics Laboratories, Inc. Corps façonnes contenant des fibres organiques courtes
US5070587A (en) * 1989-08-17 1991-12-10 Tocalo Co., Ltd. Roll for use in heat treating furnace and method of producing the same
EP0538073A2 (fr) * 1991-10-18 1993-04-21 Fujitsu Limited Procédé pour la préparation d'articles frittés et corps magnétique
EP0639540A1 (fr) * 1993-07-16 1995-02-22 FIAT AUTO S.p.A. Procédé de fabrication de feuilles métalliques et/ou en matière céramique par frittage de poudres et produits dérivés obtenus par le procédé
DE4332971A1 (de) * 1993-09-28 1995-03-30 Fischer Artur Werke Gmbh Verfahren zur Herstellung von ineinandergreifenden Teilen

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0115104A1 (fr) * 1983-01-24 1984-08-08 Sumitomo Chemical Company, Limited Préparation de corps minéraux frittés
WO1990009461A2 (fr) * 1989-02-15 1990-08-23 Technical Ceramics Laboratories, Inc. Corps façonnes contenant des fibres organiques courtes
US5070587A (en) * 1989-08-17 1991-12-10 Tocalo Co., Ltd. Roll for use in heat treating furnace and method of producing the same
EP0538073A2 (fr) * 1991-10-18 1993-04-21 Fujitsu Limited Procédé pour la préparation d'articles frittés et corps magnétique
EP0639540A1 (fr) * 1993-07-16 1995-02-22 FIAT AUTO S.p.A. Procédé de fabrication de feuilles métalliques et/ou en matière céramique par frittage de poudres et produits dérivés obtenus par le procédé
DE4332971A1 (de) * 1993-09-28 1995-03-30 Fischer Artur Werke Gmbh Verfahren zur Herstellung von ineinandergreifenden Teilen

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999021709A3 (fr) * 1997-10-29 1999-07-08 Koninkl Philips Electronics Nv Procede de production d'un composant electronique multicouche
WO1999021709A2 (fr) * 1997-10-29 1999-05-06 Koninklijke Philips Electronics N.V. Procede de production d'un composant electronique multicouche
US6322746B1 (en) 1999-06-15 2001-11-27 Honeywell International, Inc. Co-sintering of similar materials
WO2000076697A2 (fr) * 1999-06-15 2000-12-21 Honeywell International Inc. Co-frittage de materiaux similaires
WO2000076697A3 (fr) * 1999-06-15 2001-06-28 Honeywell Int Inc Co-frittage de materiaux similaires
US6563093B2 (en) 1999-06-23 2003-05-13 Robert Bosch Gmbh Ceramic pin heating element with integrated connector contacts and method for making same
WO2001000378A1 (fr) * 1999-06-23 2001-01-04 Robert Bosch Gmbh Element chauffant a pointe ceramique avec contacts integres et procede permettant de produire cet element
EP1570804A1 (fr) * 2004-03-05 2005-09-07 Straumann Holding AG Objet dentaire et méthode de manufacture via moulage par injection
US7718100B2 (en) 2004-03-05 2010-05-18 Straumann Holding Ag Dental device and method to manufacture the same
DE102011102456A1 (de) * 2011-05-25 2012-11-29 Karlsruher Institut für Technologie Bindemittelsystem für thermoplastische Formmassen für Niederdruckspritzguss
DE102011102456B4 (de) * 2011-05-25 2014-03-06 Karlsruher Institut für Technologie Verfahren für die Entbinderung von thermoplastischen Massen beim Niederdruckspritzgießen
DE102013221011A1 (de) * 2013-10-16 2015-04-16 Bayerische Motoren Werke Aktiengesellschaft Verfahren zur Herstellung eines keramischen Formteils, Verwendung von sekundärer Oxidkeramik und Spritzgussvorrichtung zur Herstellung eines keramischen Formteils
CN115502391A (zh) * 2022-09-15 2022-12-23 浙江省冶金研究院有限公司 一种表面陶瓷硬化粉末高速钢的制备方法
CN115502391B (zh) * 2022-09-15 2024-01-09 浙江省冶金研究院有限公司 一种表面陶瓷硬化粉末高速钢的制备方法

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