Contributor contact details |
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xiii | |
Preface |
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xvii | |
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1 Metal powder injection molding (MIM): key trends and markets |
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1 | (26) |
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1.1 Introduction and background |
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1 | (1) |
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2 | (2) |
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4 | (2) |
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1.4 Statistical highlights |
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6 | (3) |
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9 | (1) |
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10 | (2) |
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12 | (1) |
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1.8 Metal powder injection molding market by region |
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13 | (1) |
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1.9 Metal powder injection molding market by application |
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14 | (1) |
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1.10 Market opportunities |
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15 | (6) |
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1.11 Production sophistication |
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21 | (2) |
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23 | (1) |
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1.13 Sources of further information |
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23 | (4) |
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27 | (154) |
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2 Designing for metal injection molding (MIM) |
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29 | (21) |
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29 | (2) |
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2.2 Available materials and properties |
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31 | (4) |
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2.3 Dimensional capability |
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35 | (1) |
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35 | (1) |
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35 | (5) |
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2.6 Design considerations |
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40 | (9) |
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2.7 Sources of further information |
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49 | (1) |
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3 Powders for metal injection molding (MIM) |
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50 | (14) |
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50 | (1) |
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3.2 Ideal MIM powder characteristics |
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51 | (4) |
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3.3 Characterizing MIM powders |
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55 | (2) |
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3.4 Different MIM powder fabrication techniques |
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57 | (4) |
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3.5 Different alloying methods |
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61 | (1) |
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62 | (2) |
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4 Powder binder formulation and compound manufacture in metal injection molding (MIM) |
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64 | (29) |
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4.1 Introduction: the role of binders |
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64 | (2) |
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4.2 Binder chemistry and constituents |
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66 | (4) |
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4.3 Binder properties and effects on feedstock |
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70 | (14) |
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84 | (4) |
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4.5 Case studies: lab scale and commercial formulations |
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88 | (1) |
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89 | (4) |
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5 Tooling for metal injection molding (MIM) |
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93 | (16) |
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93 | (1) |
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5.2 General design and function of injection molding machines |
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94 | (2) |
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5.3 Elements of the tool set |
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96 | (2) |
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98 | (6) |
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5.5 Special features and instrumentation |
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104 | (2) |
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5.6 Supporting software and economic aspects |
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106 | (2) |
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5.7 Sources of further information |
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108 | (1) |
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6 Molding of components in metal injection molding (MIM) |
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109 | (24) |
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109 | (1) |
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6.2 Injection molding equipment |
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110 | (5) |
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115 | (1) |
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6.4 Injection molding process |
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116 | (13) |
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6.5 Common defects in MIM |
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129 | (2) |
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131 | (2) |
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7 Debinding and sintering of metal injection molding (MIM) components |
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133 | (48) |
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133 | (3) |
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136 | (8) |
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144 | (3) |
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147 | (14) |
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161 | (6) |
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167 | (2) |
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169 | (7) |
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176 | (1) |
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176 | (2) |
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178 | (1) |
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178 | (3) |
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181 | (124) |
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8 Characterization of feedstock in metal injection molding (MIM) |
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183 | (14) |
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183 | (3) |
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186 | (4) |
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190 | (3) |
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193 | (1) |
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8.5 Pressure-volume-temperature (PVT) |
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194 | (1) |
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195 | (1) |
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196 | (1) |
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196 | (1) |
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9 Modeling and simulation of metal injection molding (MIM) |
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197 | (38) |
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9.1 Modeling and simulation of the mixing process |
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197 | (6) |
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9.2 Modeling and simulation of the injection molding process |
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203 | (12) |
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9.3 Modeling and simulation of the thermal debinding process |
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215 | (9) |
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9.4 Modeling and simulation of the sintering process |
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224 | (6) |
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230 | (1) |
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231 | (4) |
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10 Common defects in metal injection molding (MIM) |
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235 | (19) |
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235 | (1) |
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236 | (2) |
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238 | (5) |
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243 | (7) |
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250 | (1) |
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251 | (1) |
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252 | (2) |
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11 Qualification of metal injection molding (MIM) |
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254 | (11) |
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254 | (1) |
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11.2 The metal injection molding process |
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255 | (1) |
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11.3 Product qualification method |
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255 | (2) |
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11.4 MIM prototype methodology |
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257 | (1) |
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258 | (2) |
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11.6 Understanding of control parameters |
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260 | (3) |
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263 | (1) |
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11.8 Sources of further information |
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263 | (2) |
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12 Control of carbon content in metal injection molding (MIM) |
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265 | (40) |
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12.1 Introduction: the importance of carbon control |
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265 | (2) |
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12.2 Methods of controlling carbon, binder elimination and process parameters affecting carbon control |
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267 | (9) |
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12.3 Control of carbon in particular materials |
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276 | (21) |
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12.4 Material properties affected by carbon content |
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297 | (1) |
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297 | (8) |
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Part III Special metal injection molding processes |
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305 | (86) |
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13 Micro metal injection molding (MicroMIM) |
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307 | (31) |
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307 | (1) |
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13.2 Potential of powder injection molding for micro-technology |
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308 | (1) |
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13.3 Micro-manufacturing methods for tool making |
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309 | (4) |
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13.4 Powder injection molding of micro components |
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313 | (12) |
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13.5 Multi-component micro powder injection molding |
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325 | (3) |
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13.6 Simulation of MicroMIM |
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328 | (2) |
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13.7 Conclusion and future trends |
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330 | (1) |
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13.8 Sources of further information and advice |
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331 | (1) |
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332 | (6) |
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14 Two-material/two-color powder metal injection molding (2C-PIM) |
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338 | (11) |
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338 | (1) |
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14.2 Injection molding technology |
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338 | (3) |
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14.3 Debinding and sintering |
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341 | (3) |
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344 | (2) |
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346 | (1) |
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347 | (2) |
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15 Powder space holder metal injection molding (PSH-MIM) of micro-porous metals |
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349 | (42) |
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349 | (2) |
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15.2 Production methods for porous metals |
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351 | (3) |
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15.3 Formation of micro-porous structures by the PSH method |
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354 | (6) |
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15.4 Control of porous structure with the PSH method |
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360 | (9) |
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15.5 Liquid infiltration properties of micro-porous metals produced by the PSH method |
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369 | (5) |
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15.6 Dimensional accuracy of micro-porous MIM parts |
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374 | (5) |
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15.7 Functionally graded structures of micro-porous metals |
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379 | (9) |
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388 | (1) |
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388 | (1) |
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389 | (2) |
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Part IV Metal injection molding of specific materials |
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391 | (178) |
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16 Metal injection molding (MIM) of stainless steels |
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393 | (22) |
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393 | (3) |
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16.2 Stainless steels in metal injection molding (MIM) |
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396 | (7) |
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16.3 Applications of MIM stainless steels |
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403 | (6) |
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409 | (1) |
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410 | (5) |
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17 Metal injection molding (MIM) of titanium and titanium alloys |
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415 | (31) |
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415 | (1) |
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17.2 Challenges of MIM of titanium |
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416 | (6) |
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17.3 Basics of processing |
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422 | (3) |
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17.4 Mechanical properties |
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425 | (7) |
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432 | (3) |
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17.6 Special applications |
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435 | (5) |
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17.7 Conclusion and future trends |
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440 | (1) |
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17.8 Sources of further information |
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441 | (1) |
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441 | (5) |
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18 Metal injection molding (MIM) of thermal management materials in microelectronics |
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446 | (41) |
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446 | (1) |
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18.2 Heat dissipation in microelectronics |
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447 | (4) |
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451 | (10) |
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461 | (13) |
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474 | (8) |
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482 | (1) |
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482 | (5) |
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19 Metal injection molding (MIM) of soft magnetic materials |
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487 | (29) |
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487 | (2) |
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489 | (8) |
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497 | (9) |
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506 | (7) |
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513 | (1) |
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514 | (2) |
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20 Metal injection molding (MIM) of high-speed tool steels |
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516 | (10) |
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516 | (1) |
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20.2 Tool steel MIM processing |
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517 | (6) |
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20.3 Mechanical properties |
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523 | (2) |
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525 | (1) |
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21 Metal injection molding (MIM) of heavy alloys, refractory metals, and hardmetals |
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526 | (43) |
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526 | (1) |
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527 | (2) |
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21.3 Feedstock formulation concerns |
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529 | (5) |
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534 | (10) |
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544 | (10) |
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554 | (6) |
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560 | (9) |
Index |
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569 | |