Suitability of PEG/PMMA-based metal injection moulding feedstock: an experimental study

The International Journal of Advanced Manufacturing Technology - Tập 80 Số 9 - Trang 1665-1671 - 2015
Hayat, Muhammad Dilawer1, Li, Tao2, Wen, Guian1, Cao, Peng1
1Department of Chemical and Materials Engineering, University of Auckland, Auckland, New Zealand
2Singapore Institute of Manufacturing Engineering (SIMTech), Singapore, Singapore

Tóm tắt

Due to environment-friendly nature, water-soluble binder systems have received much attention in recent years. Polyethylene glycol (PEG) and polymethyl methacrylate (PMMA) binder system is one such example and has been widely reported in the literature. In this paper, a comprehensive investigation of PEG/PMMA binder system has been carried out. Feedstocks were made using stainless steel 17-4PH powder, and subsequently, conventional and micrometal injection moulding (μMIM) processes were carried out. Differential scanning calorimetry (DSC) and fracture surface analysis of moulded samples were performed for complete evaluation. It was found that despite great potential, there are certain drawbacks associated with this binder system. The main problem is the formation of shrinkage voids during solidification. It is proposed that this binder system is more suitable for μMIM process that has an inherently higher cooling rate.

Tài liệu tham khảo

citation_journal_title=J Mater Process Technol; citation_title=A new binder for powder injection molding titanium and other reactive metals; citation_author=SK Weil, E Nyberg, K Simmons; citation_volume=176; citation_issue=1-3; citation_publication_date=2006; citation_pages=205-209; citation_doi=10.1016/j.jmatprotec.2006.03.154; citation_id=CR1 citation_journal_title=Mater Manuf Process; citation_title=Scientific and technological progress in binder burnout from metal injection molded compacts; citation_author=HH Angermann, OVD Biest; citation_volume=10; citation_issue=3; citation_publication_date=1995; citation_pages=439-451; citation_doi=10.1080/10426919508935037; citation_id=CR2 citation_journal_title=Metall Mater Trans A; citation_title=Development and design of binder systems for titanium metal Injection molding: an overview; citation_author=G Wen, P Cao, B Gabbitas, D Zhang, N Edmonds; citation_volume=44; citation_issue=3; citation_publication_date=2012; citation_pages=1530-1547; citation_doi=10.1007/s11661-012-1485-x; citation_id=CR3 Rivers RD (1978) Method of injection molding powder metal parts. USA Patent 4113480 Cao MY, O’Connor JW (1992) Chung CI A new water-soluble solid polymer solution binder for powder injection moulding. In: Powder Metallurgy World Congress. Princeton, San Francisco, APMI citation_journal_title=Key Eng Mater; citation_title=Powder injection moulding of alumina using PEG/PVB binder systems; citation_author=N Chuankrerkkul, P Sooksaen, P Pakunthod, T Kosalwit, W Pinthong; citation_volume=545; citation_publication_date=2013; citation_pages=173-176; citation_doi=10.4028/www.scientific.net/KEM.545.173; citation_id=CR6 citation_journal_title=Powder Technol; citation_title=Effect of PEG molecular weight on rheological properties of Ti-MIM feedstocks and water debinding behaviour; citation_author=MD Hayat, G Wen, MF Zulkifli, P Cao; citation_volume=270; citation_issue=0; citation_publication_date=2015; citation_pages=296-301; citation_doi=10.1016/j.powtec.2014.10.035; citation_id=CR7 citation_title=Control of carbon content in metal injection molding (MIM); citation_inbook_title=Handbook of metal injection molding; citation_publication_date=2012; citation_pages=265-304; citation_id=CR8; citation_author=G Herranz; citation_publisher=Woodhead Publishing citation_journal_title=J Mater Process Technol; citation_title=Metal injection moulding of CP-Ti components for biomedical applications; citation_author=AT Sidambe, IA Figueroa, HGC Hamilton, I Todd; citation_volume=212; citation_issue=7; citation_publication_date=2012; citation_pages=1591-1597; citation_doi=10.1016/j.jmatprotec.2012.03.001; citation_id=CR9 Liu W, Xie Z, Zhang X, Jia C, Cheng L, Liu G, Xue W (2014) Optimisation of compositions of PEG/PMMA binder system in ceramic injection moulding via water debinding. Adv Appl Ceram 0 (0):1743676114Y.0000000190. doi: 10.1179/1743676114Y.0000000190 citation_journal_title=Chiang Mai J Sci; citation_title=Application of polyethylene glycol and polymethyl methacrylate as a binder for powder injection moulding of hardmetals; citation_author=N Chuankrerkkul, PF Messer, HA Davies; citation_volume=35; citation_issue=1; citation_publication_date=2008; citation_pages=188-195; citation_id=CR11 citation_journal_title=Key Eng Mater; citation_title=Debinding kinetics of a water soluble binder system for titanium alloys metal injection moulding; citation_author=G Chen, G Wen, N Edmonds, P Cao, YM Li; citation_volume=520; citation_publication_date=2012; citation_pages=174-180; citation_doi=10.4028/www.scientific.net/KEM.520.174; citation_id=CR12 citation_journal_title=J Mater Process Technol; citation_title=The influence of PMMA content on the properties of 316L stainless steel MIM compact; citation_author=MA Omar, HA Davies, PF Messer, B Ellis; citation_volume=113; citation_issue=1–3; citation_publication_date=2001; citation_pages=477-481; citation_doi=10.1016/S0924-0136(01)00641-0; citation_id=CR13 citation_journal_title=J Appl Sci Res; citation_title=Optimizing injection parameter of metal injection molding processes using the feedstock of 16 μm stainless steel powder (SS316L), PEG, PMMA and stearic acid; citation_author=AB Sulong, N Muhamad, A Arifin, KB Yong; citation_volume=8; citation_issue=6; citation_publication_date=2012; citation_pages=2998-3003; citation_id=CR14 citation_journal_title=Powder Metall; citation_title=Injection moulding of 316L stainless steel powder using novel binder system; citation_author=MY Anwar, PF Messer, B Ellis, HA Davies; citation_volume=38; citation_issue=2; citation_publication_date=1995; citation_pages=113-119; citation_doi=10.1179/pom.1995.38.2.113; citation_id=CR15 Ibrahim MHI, Muhamad N, Sulong AB, Murtadhahadi, Jamaluin KR, Ahmat S, Nor NHM (2008) Water atomised stainless steel powder for micro metal injection molding: optimization of rheological properties In: Malaysian Metallurgical Conference, UKM, Bangi, Malaysia, Asian Network for Scientific Information Mark HF (1986) 1,2-Expoxide polymers: ethylene oxide polymers and copolymers. Encyclopedia of polymer science and engineering. Wiley McCrum NG, Buckley CP, Bucknall CB (1997) Principles of polymer engineering. 2nd edition. Oxford University Press citation_journal_title=Langmuir; citation_title=Glass transition temperature and conformational changes of poly(methyl methacrylate) thin films determined by a two-dimensional map representation of temperature-dependent reflection–absorption FTIR spectra; citation_author=HS Shin, YM Jung, TY Oh, T Chang, SB Kim, DH Lee, I Noda; citation_volume=18; citation_issue=15; citation_publication_date=2002; citation_pages=5953-5958; citation_doi=10.1021/la020258y; citation_id=CR19 Groeninckx G, Vanneste M, Everaert V (2003) Crystallization, morphological structure, and melting of polymer blends. In: Utracki LA (ed) Polymer blends handbook, Springer Netherlands, pp 203-294. doi: 10.1007/0-306-48244-4_3 citation_journal_title=Thamar Univ J Nat Appl Sci A; citation_title=Characterization and solution properties of poly(methyl metha-acrylate)–poly(ethylene glycol) lends; citation_author=AM Al-Hussam, SM Aqeel, MQ Al-Gunaid; citation_volume=4; citation_publication_date=2011; citation_pages=67-75; citation_id=CR21 citation_journal_title=Mater Res Innov; citation_title=Study on surface structure and properties of PMMA/PEG copolymer coatings; citation_author=W Zhang, XM Zhang; citation_volume=18; citation_issue=S2; citation_publication_date=2014; citation_pages=S2-1028-S1022-1033; citation_doi=10.1179/1432891714Z.000000000474; citation_id=CR22 citation_journal_title=J Appl Polym Sci; citation_title=Poly(ethylene glycol)/poly(methyl methacrylate) blends as novel form-stable phase-change materials for thermal energy storage; citation_author=A Sarı, C Alkan, A Karaipekli, O Uzun; citation_volume=116; citation_issue=2; citation_publication_date=2010; citation_pages=929-933; citation_id=CR23 citation_journal_title=Chin J Polym Sci; citation_title=Effects of blending chitosan with PEG on surface morphology, crystallization and thermal properties; citation_author=L-h He, R Xue, D-b Yang, Y Liu, R Song; citation_volume=27; citation_issue=04; citation_publication_date=2009; citation_pages=501-510; citation_doi=10.1142/S0256767909004175; citation_id=CR24 citation_journal_title=Pharm Res; citation_title=Effects of sugars and polymers on crystallization of poly(ethylene glycol) in frozen solutions: phase separation between incompatible polymers; citation_author=I K-i, S Yoshioka, S Kojima, T Randolph, J Carpenter; citation_volume=13; citation_issue=9; citation_publication_date=1996; citation_pages=1393-1400; citation_doi=10.1023/A:1016086319851; citation_id=CR25 Fort J, Krill S, Law D, Qiu Y, Schmitt E (2007) Inhibitors of crystallization in a solid dispersion. USA Patent US20070249692 citation_title=Characterization of polymer blends: miscibility, morphology and interfaces; citation_publication_date=2015; citation_id=CR27; citation_author=S Thomas; citation_author=Y Grohens; citation_author=P Jyotishkumar; citation_publisher=Wiley-VCH Verlag GmbH citation_journal_title=Polym Bull; citation_title=Solid state NMR study of poly(methyl methacrylate)/polyvinylpyrrolidone blends; citation_author=EP Silva, MIB Tavares; citation_volume=41; citation_issue=3; citation_publication_date=1998; citation_pages=307-310; citation_doi=10.1007/s002890050367; citation_id=CR28 citation_journal_title=Polym Int; citation_title=Crystallization behavior and hydrophilicity of poly(vinylidene fluoride)/poly(methyl methacrylate)/poly(vinyl pyrrolidone) ternary blends; citation_author=J Cheng, S Wang, S Chen, J Zhang, X Wang; citation_volume=61; citation_issue=3; citation_publication_date=2012; citation_pages=477-484; citation_doi=10.1002/pi.3185; citation_id=CR29 Li Y, Ma Q, Huang C, Liu G (2013) Crystallization of poly (ethylene glycol) in poly (methyl methacrylate) networks. Mater Sci 19 (2). doi:10.5755/j01.ms.19.2.4430 citation_journal_title=Polym Adv Technol; citation_title=Differential scanning calorimetry studies on poly(ethylene glycol) with different molecular weights for thermal energy storage materials; citation_author=K Pielichowski, K Flejtuch; citation_volume=13; citation_issue=10-12; citation_publication_date=2002; citation_pages=690-696; citation_doi=10.1002/pat.276; citation_id=CR31 Ren J (2010) Modification of PLA. In: Biodegradable poly(lactic acid): synthesis, modification, processing and applications. Springer Berlin Heidelberg, pp 38-141. doi: 10.1007/978-3-642-17596-1_4 citation_journal_title=Macromolecules; citation_title=Isothermal crystallization of poly(ε-caprolactone–ethylene glycol) block copolymers; citation_author=B Bogdanov, A Vidts, E Schacht, H Berghmans; citation_volume=32; citation_issue=3; citation_publication_date=1999; citation_pages=726-731; citation_doi=10.1021/ma980226a; citation_id=CR33 citation_journal_title=JOM; citation_title=Solidification shrinkage defects in electronic solders; citation_author=G Wable, S Chada, B Neal, R Fournelle; citation_volume=57; citation_issue=6; citation_publication_date=2005; citation_pages=38-42; citation_doi=10.1007/s11837-005-0134-x; citation_id=CR34 citation_journal_title=Arch Found Eng; citation_title=Automatic inspection of surface defects in die castings after machining; citation_author=SJ Swillo, M Perzyk; citation_volume=11; citation_issue=3; citation_publication_date=2011; citation_pages=231-236; citation_id=CR35