Handbook of Metal Injection Molding

Handbook of Metal Injection Molding

1st Edition - June 11, 2012

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  • Editor: Donald Heaney
  • eBook ISBN: 9780857096234
  • Hardcover ISBN: 9780857090669

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Description

Metal injection molding combines the most useful characteristics of powder metallurgy and plastic injection molding to facilitate the production of small, complex-shaped metal components with outstanding mechanical properties. The Handbook of metal injection molding provides an authoritative guide to this important technology and its applications.Part one discusses the fundamentals of the metal injection molding process with chapters on topics such as component design, important powder characteristics, compound manufacture, tooling design, molding optimization, debinding, and sintering. Part two provides a detailed review of quality issues, including feedstock characterisation, modeling and simulation, methods to qualify a MIM process, common defects and carbon content control. Special metal injection molding processes are the focus of part three, which provides comprehensive coverage of micro components, two material/two color structures, and porous metal techniques. Finally, part four explores metal injection molding of particular materials, including stainless steels, titanium and titanium alloys, thermal management alloys, high speed tool steels, heavy alloys, refractory metals, hard metals and soft magnetic alloys.With its distinguished editor and expert team of international contributors, the Handbook of metal injection molding is an essential guide for all those involved in the high-volume manufacture of small precision parts, across a wide range of high-tech industries such as microelectronics, biomedical and aerospace engineering.

Key Features

  • Provides an authoritative guide to metal injection molding and its applications
  • Discusses the fundamentals of the metal injection molding processes and covers topics such as component design, important powder characteristics, compound manufacture, tooling design, molding optimization, debinding, and sintering
  • Comprehensively examines quality issues such as feedstock characterization, modeling and simulation, common defects and carbon content control

Readership

High-volume manufacturers of small precision parts; aerospace, biomedical, dental, automotive, electronics, telecommunications, defense and other high-tech industries; metal fabrication companies

Table of Contents

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    Preface

    Chapter 1: Metal powder injection molding (MIM): key trends and markets

    Abstract:

    1.1 Introduction and background

    1.2 History of success

    1.3 Industry structure

    1.4 Statistical highlights

    1.5 Industry shifts

    1.6 Sales situation

    1.7 Market statistics

    1.8 Metal powder injection molding market by region

    1.9 Metal powder injection molding market by application

    1.10 Market opportunities

    1.11 Production sophistication

    1.12 Conclusion

    Part I: Processing

    Chapter 2: Designing for metal injection molding (MIM)

    Abstract:

    2.1 Introduction

    2.2 Available materials and properties

    2.3 Dimensional capability

    2.4 Surface finish

    2.5 Tooling artifacts

    2.6 Design considerations

    Chapter 3: Powders for metal injection molding (MIM)

    Abstract:

    3.1 Introduction

    3.2 Ideal MIM powder characteristics

    3.3 Characterizing MIM powders

    3.4 Different MIM powder fabrication techniques

    3.5 Different alloying methods

    Chapter 4: Powder binder formulation and compound manufacture in metal injection molding (MIM)

    Abstract:

    4.1 Introduction: the role of binders

    4.2 Binder chemistry and constituents

    4.3 Binder properties and effects on feedstock

    4.4 Mixing technologies

    4.5 Case studies: lab scale and commercial formulations

    Chapter 5: Tooling for metal injection molding (MIM)

    Abstract:

    5.1 Introduction

    5.2 General design and function of injection molding machines

    5.3 Elements of the tool set

    5.4 Tool design options

    5.5 Special features and instrumentation

    5.6 Supporting software and economic aspects

    Chapter 6: Molding of components in metal injection molding (MIM)

    Abstract:

    6.1 Introduction

    6.2 Injection molding equipment

    6.3 Auxiliary equipment

    6.4 Injection molding process

    6.5 Common defects in MIM

    Chapter 7: Debinding and sintering of metal injection molding (MIM) components

    Abstract:

    7.1 Introduction

    7.2 Primary debinding

    7.3 Secondary debinding

    7.4 Sintering

    7.5 MIM materials

    7.6 Settering

    7.7 MIM furnaces

    7.8 Furnace profiles

    7.9 Summary

    7.10 Acknowledgements

    Part II: Quality issues

    Chapter 8: Characterization of feedstock in metal injection molding (MIM)

    Abstract:

    8.1 Introduction

    8.2 Rheology

    8.3 Thermal analysis

    8.4 Thermal conductivity

    8.5 Pressure-volume-temperature (PVT)

    8.6 Conclusions

    8.7 Acknowledgments

    Chapter 9: Modeling and simulation of metal injection molding (MIM)

    Abstract:

    9.1 Modeling and simulation of the mixing process

    9.2 Modeling and simulation of the injection molding process

    9.3 Modeling and simulation of the thermal debinding process

    9.4 Modeling and simulation of the sintering process

    9.5 Conclusion

    Chapter 10: Common defects in metal injection molding (MIM)

    Abstract:

    10.1 Introduction

    10.2 Feedstock

    10.3 Molding

    10.4 Debinding

    10.5 Sintering

    10.6 Conclusion

    Chapter 11: Qualification of metal injection molding (MIM)

    Abstract:

    11.1 Introduction

    11.2 The metal injection molding process

    11.3 Product qualification method

    11.4 MIM prototype methodology

    11.5 Process control

    11.6 Understanding of control parameters

    11.7 Conclusion

    Chapter 12: Control of carbon content in metal injection molding (MIM)

    Abstract:

    12.1 Introduction: the importance of carbon control

    12.2 Methods of controlling carbon, binder elimination and process parameters affecting carbon control

    12.3 Control of carbon in particular materials

    12.4 Material properties affected by carbon content

    Part III: Special metal injection molding processes

    Chapter 13: Micro metal injection molding (MicroMIM)

    Abstract:

    13.1 Introduction

    13.2 Potential of powder injection molding for microtechnology

    13.3 Micro-manufacturing methods for tool making

    13.4 Powder injection molding of micro-components

    13.5 Multi-component micro powder injection molding

    13.6 Simulation of MicroMIM

    13.7 Conclusion and future trends

    13.8 Sources of further information and advice

    Chapter 14: Two-material/two-color powder metal injection molding (2C-PIM)

    Abstract:

    14.1 Introduction

    14.2 Injection molding technology

    14.3 Debinding and sintering

    14.4 2C-PIM products

    14.5 Future trends

    Chapter 15: Powder space holder metal injection molding (PSH-MIM) of micro-porous metals

    Abstract:

    15.1 Introduction

    15.2 Production methods for porous metals

    15.3 Formation of micro-porous structures by the PSH method

    15.4 Control of porous structure with the PSH method

    15.5 Liquid infiltration properties of micro-porous metals produced by the PSH method

    15.6 Dimensional accuracy of micro-porous MIM parts

    15.7 Functionally graded structures of micro-porous metals

    15.8 Conclusion

    15.9 Acknowledgements

    Part IV: Special metal injection molding processes

    Chapter 16: Metal injection molding (MIM) of stainless steel

    Abstract:

    16.1 Introduction

    16.2 Stainless steels in metal injection molding (MIM)

    16.3 Applications of MIM stainless steels

    16.4 Acknowledgements

    Chapter 17: Metal injection molding (MIM) of titanium and titanium alloys

    Abstract:

    17.1 Introduction

    17.2 Challenges of MIM of titanium

    17.3 Basics of processing

    17.4 Mechanical properties

    17.5 Cost reduction

    17.6 Special applications

    17.7 Conclusion and future trends

    17.8 Sources of further information

    Chapter 18: Metal injection molding (MIM) of thermal management materials in microelectronics

    Abstract:

    18.1 Introduction

    18.2 Heat dissipation in microelectronics

    18.3 Copper

    18.4 Tungsten–copper

    18.5 Molybdenum–copper

    18.6 Conclusions

    Chapter 19: Metal injection molding (MIM) of soft magnetic materials

    Abstract:

    19.1 Introduction

    19.2 Fe–6.5Si

    19.3 Fe–9.5Si–5.5Al

    19.4 Fe–50Ni

    19.5 Conclusion

    Chapter 20: Metal injection molding (MIM) of high-speed tool steels

    Abstract:

    20.1 Introduction

    20.2 Tool steel MIM processing

    20.3 Mechanical properties

    Chapter 21: Metal injection molding (MIM) of heavy alloys, refractory metals, and hardmetals

    Abstract:

    21.1 Introduction

    21.2 Applications

    21.3 Feedstock formulation concerns

    21.4 Heavy alloys

    21.5 Refractory metals

    21.6 Hardmetals

    Index

Product details

  • No. of pages: 604
  • Language: English
  • Copyright: © Woodhead Publishing 2012
  • Published: June 11, 2012
  • Imprint: Woodhead Publishing
  • eBook ISBN: 9780857096234
  • Hardcover ISBN: 9780857090669

About the Editor

Donald Heaney

Donald F. Heaney is the President and CEO of Advanced Powder Products Inc., USA. He is also an adjunct Professor of Engineering Science and Mechanics at The Pennsylvania State University.

Affiliations and Expertise

President and CEO of Advanced Powder Products Inc., USA. He is also an adjunct Professor of Engineering Science and Mechanics at The Pennsylvania State University.

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