Powder blending,a homogeneous alloy powders is prepared. Depending the requirement character other alloys and lubricants may be added .Compaction,a controlled amount of the mixed powder is put into a precision die and pressed at a controlled pressure.The compacting pressure required depends on the characteristics and shape of the particles, the powder mixing ,and the lubricant used. In doing so,the loose mixing powder is consolidated and densified into a shaped model. As is comes out of the die , the part has the size and shape of the part.Sintering,the compact part is heated in a protective atmosphere furnace to a suitable temperature and the temperature is below the metal melting point .
Advantages of powder metallurgy
Products made by powder metallurgy (PM) generally do not need further finishing , because produces good surface finish.
Maintains close dimensional tolerances
Provides materials which may be heat treated for increased strength or enhanced wear resistance .
There is less wastage of raw material , can be very economical for mass production .
Complex shapes parts can be made . Provides controlled porosity for self-lubrication or filtration.
Suits to high volume parts productions requirements .
Mixing of powders
This can often involve the introduction of alloying additions in elemental powder form or the incorporation of a pressing lubricant.
Forming of the mixed powder into a compact
The dominant consolidation process involves pressing in a rigid toolset, comprising a die, punches and, possibly, mandrels or core rods. However, there are several other consolidation processes that are used in niche applications.
Sintering of the compact to enhance integrity and strength
This process step involves heating of the material, usually in a protective atmosphere, to a temperature that is below the melting point of the major constituent. In some cases, a minor constituent can form a liquid phase at sintering temperature; such cases are described as liquid phase sintering. The mechanisms involved in solid phase and liquid phase sintering are discussed briefly in a later section.
The application of finishing processes to the sintered part. In the Powder Metallurgy industry, such processes are often referred to as secondary operations.
Customized metal parts
|Product type||metal injetion molding parts powder metallurgy sintering metal parts high precision strong hardness metal components hardware|
|Material||metal , Iron , stainless steel , copper ,carbon steel|
|Process||Metal injection molding , powder metallurgy , stamping|
|Treatment||Polishing , plating ,sand blasting , PVD , coating|
|Drawing format||DWG ,IGS , STP|
|Delivery time||20 days for mass production|
Metal parts from Metal injection molding (MIM) process can be found in automotive , medical (including dental) , telecommunications , consumer products , sporting goods , electronic devices etc.
The advantages of metal injection molding for metal fabrications :
- Highest degree of design freedom for complex shapes and geometries
- Provides practical economic solutions to increasingly stringent material and product design requirements
- Functional integration of various features, such as lateral drillings, interior and exterior threads and gear teeth.
- Excellent batch to batch repeatability with exceptional process capabilities
- Very high volume production series run on fully-automatic injection molding machines using multi-cavity tools
- Components can be heat and surface treated, plated, welded and soldered
Custom metal parts