High-entropy alloys (HEAs) are attracting attention because of their excellent properties and functions; however, they are relatively expensive compared with commercial alloys. Therefore, various efforts have been made to reduce the cost of raw materials. In this study, MIM is attempted using coarse equiatomic CoCrFeMnNi HEA powders. The mixing ratio (powder:binder) for HEA feedstock preparation is explored using torque rheometer. The block-shaped green parts are fabricated through a metal injection molding process using feedstock. The thermal debinding conditions are explored by thermogravimetric analysis, and solvent and thermal debinding are performed. It is densified under various sintering conditions considering the melting point of the HEA. The final product, which contains a small amount of non-FCC phase, is manufactured at a sintering temperature of 1250°C.
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Nanopowders provide better details for micro features and surface finish in powder injection molding processes. However, the small size of such powders induces processing challenges, such as low solid loading, high feedstock viscosity, difficulty in debinding, and distinctive sintering behavior. Therefore, the optimization of process conditions for nanopowder injection molding is essential, and it should be carefully performed. In this study, the powder injection molding process for Fe nanopowder has been optimized. The feedstock has been formulated using commercially available Fe nanopowder and a wax-based binder system. The optimal solid loading has been determined from the critical solid loading, measured by a torque rheometer. The homogeneously mixed feedstock is injected as a cylindrical green body, and solvent and thermal debinding conditions are determined by observing the weight change of the sample. The influence of the sintering temperature and holding time on the density has also been investigated. Thereafter, the Vickers hardness and grain size of the sintered samples have been measured to optimize the sintering conditions.
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In this study, a finite element analysis approach is proposed to predict the fluid-structure interaction behavior of active materials for lithium-ion batteries (LIBs), which are mainly composed of graphite powder. The porous matrix of graphite powder saturated with fluid electrolyte is considered a representative volume element (RVE) model. Three different RVE models are proposed to consider the uncertainty of the powder shape and the porosity. Pwave modulus from RVE solutions are analyzed based on the microstructure and the interaction between the fluid and the graphite powder matrix. From the results, it is found that the large surface area of the active material results in low mechanical properties of LIB, which leads to poor structural durability when subjected to dynamic loads. The results obtained in this study provide useful information for predicting the mechanical safety of a battery pack.
A powder injection molding process is developed and optimized for piezoelectric PAN-PZT ceramics. Torque rheometer experiments are conducted to determine the optimal solids loading, and the rheological property of the feedstock is evaluated using a capillary rheometer. Appropriate debinding conditions are chosen using a thermal gravity analyzer, and the debound specimens are sintered using sintering conditions determined in a preliminary investigation. Piezoelectric performance measures, including the piezoelectric charge constant and dielectric constant, are measured to verify the developed process. The average values of the measured piezoelectric charge constant and dielectric constant are 455 pC/N and 1904, respectively. Powder injection molded piezoelectric ceramics produced by the optimized process show adequate piezoelectric performance compared to press-sintered piezoelectric ceramics.
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Powder injection molding (PIM), which combines the advantages of powder metallurgy and plastic injection molding technologies, has become one of the most efficient methods for the net-shape production of both metal and ceramic components. In this work, plasma display panel glass bodies are prepared by the PIM process. After sintering, the hot isostatic pressing (HIP) process is adopted for improving the density and mechanical properties of the PIMed glass bodies. The mechanical and thermal behaviors of the prepared specimens are analyzed through bending tests and dilatometric analysis, respectively. After HIPing, the flexural strength of the prepared glass body reaches up to 92.17 MPa, which is 1.273 and 2.178 times that of the fused glass body and PIMed bodies, respectively. Moreover, a thermal expansion coefficient of 7.816 × 10−6/°C is obtained, which coincides with that of the raw glass powder (7.5-8.0 × 10−6/°C), indicating that the glass body is fully densified after the HIP process.
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The sintering mechanisms of nanoscale copper powders have been investigated. A molecular dynamics (MD) simulation with the embedded-atom method (EAM) was employed for these simulations. The dimensional changes for initial-stage sintering such as characteristic lengths, neck growth, and neck angle were calculated to understand the densification behavior of copper nano-powders. Factors affecting sintering such as the temperature, powder size, and crystalline misalignment between adjacent powders have also been studied. These results could provide information of setting the processing cycles and material designs applicable to nano-powders. In addition, it is expected that MD simulation will be a foundation for the multi-scale modeling in sintering process.
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Powder injection molding is an important manufacturing technology to mass produce superalloy components with complex shape. Injection molding step is particularly important for realizing a desired shape, which requires much time and efforts finding the optimum process condition. Therefore computer aided engineering can be very useful to find proper injection molding conditions. In this study, we have conducted a finite element method based simulation for the spiral mold test of superalloy feedstock and compared the results with experimental ones. Sensitivity analysis with both of simulation and experiment reveals that the melt temperature of superalloy feedstock is the most important factor for the full filling of mold cavity. The FEM based simulation matches well the experimental results. This study contributes to the optimization of superalloy powder injection molding process.
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A magnetic powder, M-type barium hexaferrite (BaFe12O19), was consolidated with the spark plasma sintering process. Three different holding temperatures, 850°C, 875°C and 900°C were applied to the spark plasma sintering process with the same holding times, heating rates and compaction pressure of 30 MPa. The relative density was measured simultaneously with spark plasma sintering and the convergent relative density after cooling was found to be proportional to the holding temperature. The full relative density was obtained at 900°C and the total sintering time was only 33.3 min, which was much less than the conventional furnace sintering method. The higher holding temperature also led to the higher saturation magnetic moment (σs) and the higher coercivity (Hc) in the vibrating sample magnetometer measurement. The saturation magnetic moment (σs) and the coercivity (Hc) obtained at 900°C were 56.3 emu/g and 541.5 Oe for each.
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This study investigated the densification behavior of rhenium alloys including W-25 wt.%Re and Re-2W- 1Ta (pure Re) during sintering. The dilatometry experiments were carried out to obtain the
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