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 |  موضوع: كتاب Handbook of Metal Injection Molding الأحد 12 أبريل 2020, 11:53 pm | |
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أحضرت لكم كتاب
Handbook of Metal Injection Molding
Edited by
Donald F. Heaney
و المحتوى كما يلي :
Contents
Contributor contact details xiii
Preface xvii
1 Metal powder injection molding (MIM): key trends
and markets 1
R. M. GERMAN, San Diego State University, USA
1.1 Introduction and background 1
1.2 History of success 2
1.3 Industry structure 4
1.4 Statistical highlights 6
1.5 Industry shifts 9
1.6 Sales situation 10
1.7 Market statistics 12
1.8 Metal powder injection molding market by region 13
1.9 Metal powder injection molding market by application 14
1.10 Market opportunities 15
1.11 Production sophistication 21
1.12 Conclusion 23
1.13 Sources of further information 23
Part I Processing 27
2 Designing for metal injection molding (MIM) 29
D. F. HEANEY, Advanced Powder Products, Inc., USA
2.1 Introduction 29
2.2 Available materials and properties 31
2.3 Dimensional capability 35
2.4 Surface finish 35
2.5 Tooling artifacts 35
2.6 Design considerations 40
2.7 Sources of further information 49
3 Powders for metal injection molding (MIM) 50
D. F. HEANEY, Advanced Powder Products, Inc., USA
3.1 Introduction 50
3.2 Ideal MIM powder characteristics 51
3.3 Characterizing MIM powders 55
3.4 Different MIM powder fabrication techniques 57
3.5 Different alloying methods 61
3.6 References 62
4 Powder binder formulation and compound
manufacture in metal injection molding (MIM) 64
R. K. ENNETI, Global Tungsten and Powders, USA and
V. P. ONBATTUVELLI and S. V. ATRE, Oregon State
University, USA
4.1 Introduction: the role of binders 64
4.2 Binder chemistry and constituents 66
4.3 Binder properties and effects on feedstock 70
4.4 Mixing technologies 84
4.5 Case studies: lab scale and commercial formulations 88
4.6 References 89
5 Tooling for metal injection molding (MIM) 93
G. SCHLIEPER, Gammatec Engineering GmbH, Germany
5.1 Introduction 93
5.2 General design and function of injection molding machines 94
5.3 Elements of the tool set 96
5.4 Tool design options 98
5.5 Special features and instrumentation 104
5.6 Supporting software and economic aspects 106
5.7 Sources of further information 108
6 Molding of components in metal injection molding
(MIM) 109
D. F. HEANEY, Advanced Powder Products, Inc., USA
and C. D. GREENE, Treemen Industries, Inc., USA
6.1 Introduction 109
6.2 Injection molding equipment 110
6.3 Auxiliary equipment 115
6.4 Injection molding process 116
6.5 Common defects in MIM 129
vi Contents6.6 References 131
7 Debinding and sintering of metal injection molding
(MIM) components 133
S. BANERJEE, DSH Technologies LLC, USA and
C. J. JOENS, Elnik Systems LLC, USA
7.1 Introduction 133
7.2 Primary debinding 136
7.3 Secondary debinding 144
7.4 Sintering 147
7.5 MIM materials 161
7.6 Settering 167
7.7 MIM furnaces 169
7.8 Furnace profiles 176
7.9 Summary 176
7.10 Acknowledgements 178
7.11 References 178
Part II Quality issues 181
8 Characterization of feedstock in metal injection
molding (MIM) 183
H. LOBO, DatapointLabs, USA
8.1 Introduction 183
8.2 Rheology 186
8.3 Thermal analysis 190
8.4 Thermal conductivity 193
8.5 Pressure–volume–temperature (PVT) 194
8.6 Conclusions 195
8.7 Acknowledgments 196
8.8 References 196
9 Modeling and simulation of metal injection molding
(MIM) 197
T. G. KANG, Korea Aerospace University, Korea, S. AHN,
Pusan National University, Korea, S. H. CHUNG, Hyundai
Steel Co., Korea, S. T. CHUNG, CetaTech Inc., Korea,
Y. S. KWON, CetaTech, Inc., Korea, S. J. PARK,
POSTECH, Korea and R. M. GERMAN, San Diego State
University, USA
9.1 Modeling and simulation of the mixing process 197
9.2 Modeling and simulation of the injection molding process 203
Contents vii
9.3 Modeling and simulation of the thermal debinding process 215
9.4 Modeling and simulation of the sintering process 224
9.5 Conclusion 230
9.6 References 231
10 Common defects in metal injection molding (MIM) 235
K. S. HWANG, National Taiwan University, Taiwan,
R.O.C.
10.1 Introduction 235
10.2 Feedstock 236
10.3 Molding 238
10.4 Debinding 243
10.5 Sintering 250
10.6 Conclusion 251
10.7 References 252
11 Qualification of metal injection molding (MIM) 254
D. F. HEANEY, Advanced Powder Products, Inc., USA
11.1 Introduction 254
11.2 The metal injection molding process 255
11.3 Product qualification method 255
11.4 MIM prototype methodology 257
11.5 Process control 258
11.6 Understanding of control parameters 260
11.7 Conclusion 263
11.8 Sources of further information 263
12 Control of carbon content in metal injection molding
(MIM) 265
G. HERRANZ, Universidad de Castilla-La Mancha, Spain
12.1 Introduction: the importance of carbon control 265
12.2 Methods of controlling carbon, binder elimination and
process parameters affecting carbon control 267
12.3 Control of carbon in particular materials 276
12.4 Material properties affected by carbon content 297
12.5 References 297
Part III Special metal injection molding processes 305
13 Micro metal injection molding (MicroMIM) 307
V. PIOTTER, Karlsruhe Institute of Technology (KIT),
Germany
viii Contents
13.1 Introduction 307
13.2 Potential of powder injection molding for micro-technology 308
13.3 Micro-manufacturing methods for tool making 309
13.4 Powder injection molding of micro components 313
13.5 Multi-component micro powder injection molding 325
13.6 Simulation of MicroMIM 328
13.7 Conclusion and future trends 330
13.8 Sources of further information and advice 331
13.9 References 332
14 Two-material/two-color powder metal injection
molding (2C-PIM) 338
P. SURI, Heraeus Materials Technology LLC, USA
14.1 Introduction 338
14.2 Injection molding technology 338
14.3 Debinding and sintering 341
14.4 2C-PIM products 344
14.5 Future trends 346
14.6 References 347
15 Powder space holder metal injection molding
(PSH-MIM) of micro-porous metals 349
K. NISHIYABU, Kinki University, Japan
15.1 Introduction 349
15.2 Production methods for porous metals 351
15.3 Formation of micro-porous structures by the PSH method 354
15.4 Control of porous structure with the PSH method 360
15.5 Liquid infiltration properties of micro-porous metals
produced by the PSH method 369
15.6 Dimensional accuracy of micro-porous MIM parts 374
15.7 Functionally graded structures of micro-porous metals 379
15.8 Conclusion 388
15.9 Acknowledgements 388
15.10 References 389
Part IV Metal injection molding of specific materials 391
16 Metal injection molding (MIM) of stainless steels 393
J. M. TORRALBA, Institute IMDEA Materials, Universidad
Carlos III de Madrid, Spain
16.1 Introduction 393
16.2 Stainless steels in metal injection molding (MIM) 396
Contents ix
16.3 Applications of MIM stainless steels 403
16.4 Acknowledgements 409
16.5 References 410
17 Metal injection molding (MIM) of titanium and
titanium alloys 415
T. EBEL, Helmholtz-Zentrum Geesthacht, Germany
17.1 Introduction 415
17.2 Challenges of MIM of titanium 416
17.3 Basics of processing 422
17.4 Mechanical properties 425
17.5 Cost reduction 432
17.6 Special applications 435
17.7 Conclusion and future trends 440
17.8 Sources of further information 441
17.9 References 441
18 Metal injection molding (MIM) of thermal
management materials in microelectronics 446
J. L. JOHNSON, ATI Firth Sterling, USA
18.1 Introduction 446
18.2 Heat dissipation in microelectronics 447
18.3 Copper 451
18.4 Tungsten–copper 461
18.5 Molybdenum–copper 474
18.6 Conclusions 482
18.7 References 482
19 Metal injection molding (MIM) of soft magnetic
materials 487
H. MIURA, Kyushu University, Japan
19.1 Introduction 487
19.2 Fe–6.5Si 489
19.3 Fe–9.5Si–5.5Al 497
19.4 Fe–50Ni 506
19.5 Conclusion 513
19.6 References 514
x Contents
20 Metal injection molding (MIM) of high-speed tool
steels 516
N. S. MYERS, Kennametal Inc., USA and D. F. HEANEY,
Advanced Powder Products, Inc., USA
20.1 Introduction 516
20.2 Tool steel MIM processing 517
20.3 Mechanical properties 523
20.4 References 525
21 Metal injection molding (MIM) of heavy alloys,
refractory metals, and hardmetals 526
J. L. JOHNSON, ATI Firth Sterling, USA, D. F. HEANEY,
Advanced Powder Products, Inc., USA and N. S. Myers,
Kennametal Inc., USA
21.1 Introduction 526
21.2 Applications 527
21.3 Feedstock formulation concerns 529
21.4 Heavy alloys 534
21.5 Refractory metals 544
21.6 Hardmetals 554
21.7 References 560
Index 569
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