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E-grāmata: Handbook of Metal Injection Molding

Edited by (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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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.

Recenzijas

"...contains very up-to-date information on market, technological, quality and practical issues...a comprehensive book with very recent research outputs and practical examples of application." --International Journal of Environmental Studies, Vol 70, Issue 1-13

"This new book will be a most useful reference tool for MIM researchers, producers and end-users alike." --Power Injection Moulding International

Contributor contact details xiii
Preface xvii
1 Metal powder injection molding (MIM): key trends and markets
1(26)
R. M. German
1.1 Introduction and background
1(1)
1.2 History of success
2(2)
1.3 Industry structure
4(2)
1.4 Statistical highlights
6(3)
1.5 Industry shifts
9(1)
1.6 Sales situation
10(2)
1.7 Market statistics
12(1)
1.8 Metal powder injection molding market by region
13(1)
1.9 Metal powder injection molding market by application
14(1)
1.10 Market opportunities
15(6)
1.11 Production sophistication
21(2)
1.12 Conclusion
23(1)
1.13 Sources of further information
23(4)
Part I Processing
27(154)
2 Designing for metal injection molding (MIM)
29(21)
D. F. Heaney
2.1 Introduction
29(2)
2.2 Available materials and properties
31(4)
2.3 Dimensional capability
35(1)
2.4 Surface finish
35(1)
2.5 Tooling artifacts
35(5)
2.6 Design considerations
40(9)
2.7 Sources of further information
49(1)
3 Powders for metal injection molding (MIM)
50(14)
D. F. Heaney
3.1 Introduction
50(1)
3.2 Ideal MIM powder characteristics
51(4)
3.3 Characterizing MIM powders
55(2)
3.4 Different MIM powder fabrication techniques
57(4)
3.5 Different alloying methods
61(1)
3.6 References
62(2)
4 Powder binder formulation and compound manufacture in metal injection molding (MIM)
64(29)
R. K. Enneti
V. P. Onbattuvelli
S. V. Atre
4.1 Introduction: the role of binders
64(2)
4.2 Binder chemistry and constituents
66(4)
4.3 Binder properties and effects on feedstock
70(14)
4.4 Mixing technologies
84(4)
4.5 Case studies: lab scale and commercial formulations
88(1)
4.6 References
89(4)
5 Tooling for metal injection molding (MIM)
93(16)
G. Schlieper
5.1 Introduction
93(1)
5.2 General design and function of injection molding machines
94(2)
5.3 Elements of the tool set
96(2)
5.4 Tool design options
98(6)
5.5 Special features and instrumentation
104(2)
5.6 Supporting software and economic aspects
106(2)
5.7 Sources of further information
108(1)
6 Molding of components in metal injection molding (MIM)
109(24)
D. F. Heaney
C. D. Greene
6.1 Introduction
109(1)
6.2 Injection molding equipment
110(5)
6.3 Auxiliary equipment
115(1)
6.4 Injection molding process
116(13)
6.5 Common defects in MIM
129(2)
6.6 References
131(2)
7 Debinding and sintering of metal injection molding (MIM) components
133(48)
S. Banerjee
C. J. Joens
7.1 Introduction
133(3)
7.2 Primary debinding
136(8)
7.3 Secondary debinding
144(3)
7.4 Sintering
147(14)
7.5 MIM materials
161(6)
7.6 Settering
167(2)
7.7 MIM furnaces
169(7)
7.8 Furnace profiles
176(1)
7.9 Summary
176(2)
7.10 Acknowledgements
178(1)
7.11 References
178(3)
Part II Quality issues
181(124)
8 Characterization of feedstock in metal injection molding (MIM)
183(14)
H. Lobo
8.1 Introduction
183(3)
8.2 Rheology
186(4)
8.3 Thermal analysis
190(3)
8.4 Thermal conductivity
193(1)
8.5 Pressure-volume-temperature (PVT)
194(1)
8.6 Conclusions
195(1)
8.7 Acknowledgments
196(1)
8.8 References
196(1)
9 Modeling and simulation of metal injection molding (MIM)
197(38)
T. G. Kang
S. Ahn
S. H. Chung
S. T. Chung
Y. S. Kwon
S. J. Park
R. M. German
9.1 Modeling and simulation of the mixing process
197(6)
9.2 Modeling and simulation of the injection molding process
203(12)
9.3 Modeling and simulation of the thermal debinding process
215(9)
9.4 Modeling and simulation of the sintering process
224(6)
9.5 Conclusion
230(1)
9.6 References
231(4)
10 Common defects in metal injection molding (MIM)
235(19)
K. S. Hwang
10.1 Introduction
235(1)
10.2 Feedstock
236(2)
10.3 Molding
238(5)
10.4 Debinding
243(7)
10.5 Sintering
250(1)
10.6 Conclusion
251(1)
10.7 References
252(2)
11 Qualification of metal injection molding (MIM)
254(11)
D. F. Heaney
11.1 Introduction
254(1)
11.2 The metal injection molding process
255(1)
11.3 Product qualification method
255(2)
11.4 MIM prototype methodology
257(1)
11.5 Process control
258(2)
11.6 Understanding of control parameters
260(3)
11.7 Conclusion
263(1)
11.8 Sources of further information
263(2)
12 Control of carbon content in metal injection molding (MIM)
265(40)
G. Herranz
12.1 Introduction: the importance of carbon control
265(2)
12.2 Methods of controlling carbon, binder elimination and process parameters affecting carbon control
267(9)
12.3 Control of carbon in particular materials
276(21)
12.4 Material properties affected by carbon content
297(1)
12.5 References
297(8)
Part III Special metal injection molding processes
305(86)
13 Micro metal injection molding (MicroMIM)
307(31)
V. Piotter
13.1 Introduction
307(1)
13.2 Potential of powder injection molding for micro-technology
308(1)
13.3 Micro-manufacturing methods for tool making
309(4)
13.4 Powder injection molding of micro components
313(12)
13.5 Multi-component micro powder injection molding
325(3)
13.6 Simulation of MicroMIM
328(2)
13.7 Conclusion and future trends
330(1)
13.8 Sources of further information and advice
331(1)
13.9 References
332(6)
14 Two-material/two-color powder metal injection molding (2C-PIM)
338(11)
P. Suri
14.1 Introduction
338(1)
14.2 Injection molding technology
338(3)
14.3 Debinding and sintering
341(3)
14.4 2C-PIM products
344(2)
14.5 Future trends
346(1)
14.6 References
347(2)
15 Powder space holder metal injection molding (PSH-MIM) of micro-porous metals
349(42)
K. Nishiyabu
15.1 Introduction
349(2)
15.2 Production methods for porous metals
351(3)
15.3 Formation of micro-porous structures by the PSH method
354(6)
15.4 Control of porous structure with the PSH method
360(9)
15.5 Liquid infiltration properties of micro-porous metals produced by the PSH method
369(5)
15.6 Dimensional accuracy of micro-porous MIM parts
374(5)
15.7 Functionally graded structures of micro-porous metals
379(9)
15.8 Conclusion
388(1)
15.9 Acknowledgements
388(1)
15.10 References
389(2)
Part IV Metal injection molding of specific materials
391(178)
16 Metal injection molding (MIM) of stainless steels
393(22)
J. M. Torralab
16.1 Introduction
393(3)
16.2 Stainless steels in metal injection molding (MIM)
396(7)
16.3 Applications of MIM stainless steels
403(6)
16.4 Acknowledgements
409(1)
16.5 References
410(5)
17 Metal injection molding (MIM) of titanium and titanium alloys
415(31)
T. Ebel
17.1 Introduction
415(1)
17.2 Challenges of MIM of titanium
416(6)
17.3 Basics of processing
422(3)
17.4 Mechanical properties
425(7)
17.5 Cost reduction
432(3)
17.6 Special applications
435(5)
17.7 Conclusion and future trends
440(1)
17.8 Sources of further information
441(1)
17.9 References
441(5)
18 Metal injection molding (MIM) of thermal management materials in microelectronics
446(41)
J. L. Johnson
18.1 Introduction
446(1)
18.2 Heat dissipation in microelectronics
447(4)
18.3 Copper
451(10)
18.4 Tungsten-copper
461(13)
18.5 Molybdenum-copper
474(8)
18.6 Conclusions
482(1)
18.7 References
482(5)
19 Metal injection molding (MIM) of soft magnetic materials
487(29)
H. Miura
19.1 Introduction
487(2)
19.2 Fe-6.5Si
489(8)
19.3 Fe-9.5Si-5.5Al
497(9)
19.4 Fe-50Ni
506(7)
19.5 Conclusion
513(1)
19.6 References
514(2)
20 Metal injection molding (MIM) of high-speed tool steels
516(10)
N. S. Myers
D. F. Heaney
20.1 Introduction
516(1)
20.2 Tool steel MIM processing
517(6)
20.3 Mechanical properties
523(2)
20.4 References
525(1)
21 Metal injection molding (MIM) of heavy alloys, refractory metals, and hardmetals
526(43)
J. L. Johnson
D. F. Heaney
N. S. Myers
21.1 Introduction
526(1)
21.2 Applications
527(2)
21.3 Feedstock formulation concerns
529(5)
21.4 Heavy alloys
534(10)
21.5 Refractory metals
544(10)
21.6 Hardmetals
554(6)
21.7 References
560(9)
Index 569
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.