Antusch, S.

Piotter, V.

Rieth, M.

English

KITopen

KIT-IAM1 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013MASS PRODUCTION AND JOINING VIA MULTICOMPONENT TUNGSTEN POWDER INJECTION MOLDINGKarlsruhe Institute of Technology (KIT)Institute for Applied MaterialsSteffen Antusch, Volker Piotter, Michael Rieth18th PLANSEE SEMINAR  June 3-7, 2013KIT-IAM2 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013• Motivation• What is Powder Injection Molding (PIM)?• The PIM process for tungsten developed @ KIT• Production of multicomponent W PIM divertor parts• Summary & OutlookOutlineKIT-IAM3 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013MotivationMain function:remove eroded particlesKIT-IAM4 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013 W tile: armour material W-alloy thimble: structural material PdNi-brazing joint assembling, adjustment „handmade“ DEMO: nearly 300.000 parts lifetime nearly 2 years Reasonable manufacturing method?MotivationProducing as 2 Component W PIM partin one step fully automaticwithout additional brazingHe-cooled modular divertor with jet cooling (HEMJ)KIT-IAM5 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013What is Powder Injection Molding (PIM)?Metal Injection Molding (MIM) Ceramic Injection Molding (CIM)…manufacturing technology…KIT-IAM6 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013Al2O3ZrO2Smallest ZrO2 gear wheel of the world: outer- 275 µm What is Powder Injection Molding (PIM)?…parts produced at KIT…CopperTungstenSteelTitaniumCeramicKIT-IAM7 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013The PIM process for tungsten developed @ KITKIT-IAM8 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013The PIM process for tungsten developed @ KIT…steps for developing new PIM tools…Very important to know:- Powder properties (size, shape, surface)- Powder / Binder relationship (Feedstock)- Heat-treatment process conditions- Shrinkage (green part – finished part)Filling simulation:- Define gating system parameters (position, size, shape)- Problems (air inclusions, mold filling, premature setting)Construction of the tool Running-in tests – maybe subsequent improvementpre-tests /analyzes½ year½ year+Finished partIdeaKIT-IAM9 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013The PIM process for tungsten developed @ KIT…used powders…SEM Microstructure tungsten powder W1 SEM Microstructure tungsten powder W2Powder particle size (as delivered):Tungsten W1 [0.7 µm]Tungsten W2 [1.7 µm]Lanthanum oxide [<1.50 µm]Yttrium oxide [<2.50 µm]Doped tungsten powders(producing via wet milling for 2 h):W-2La2O3W-2Y2O3KIT-IAM10 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013The PIM process for tungsten developed @ KIT…filling simulation…KIT-IAM11 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013Production of multicomponent W PIM divertor parts…the new fully automatic PIM tool…Fully automatic mass production:50 SECONDS for 1 PartKIT-IAM12 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013Production of multicomponent W PIM divertor parts…the new fully automatic PIM tool…KIT-IAM13 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013Production of multicomponent W PIM divertor parts…the heat-treatment process…KIT-IAM14 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013Density >95% - closed porosity!!!Vickers-hardness 420 HV0.1S. Antusch et al., J. Nucl. Mater. 417 (2011) 533-535. pre-sintering pre-sintering + HIPDensity >98%Vickers-hardness 457 HV0.1SEM Microstructure pre-sintering W SEM Microstructure pre-sintering + HIP WProduction of multicomponent W PIM divertor parts…the heat-treatment process…KIT-IAM15 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013Production of multicomponent W PIM divertor partsKIT-IAM16 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013Joining without brazingS. Antusch et al., J. of Fusion Engineering and Design (2013).  High quality of the joint Material joining successful No gaps or cracks in the seam of the joining zoneProduction of multicomponent W PIM divertor partsKIT-IAM17 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013Material Theoretical density (% TD) Vickers-hardness (HV0.1) Grain size (µm)W 98.6 - 99.0 457 5 - 7W-2La2O3 98.5 - 98.9 588 >3W-2Y2O3 98.3 - 98.7 619 <3Production of multicomponent W PIM divertor partsSEM MicrostructureKIT-IAM18 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013Multicomponent Powder Injection Molding =   Mass production & joining processSummary & Outlook Time & cost effective near-net shape forming process Shape complexity & high final density Joining technique Ideal tool for scientific investigations: Rapid development of new materials Investigation of propertiesKIT-IAM19 Steffen Antusch 18th PLANSEE SEMINAR 201319.06.2013THANK YOU VERY MUCH!Niklas Denker, Sascha Enke, Jochen Heneka, Peter Holzer, Marcus Müller, Margarete Offermann, Heinz Walter, Tobias Weingärtner

Mass production and joining via multicomponent tungsten powder injection molding

https://publikationen.bibliothek.kit.edu/240091860/3816314

Mass production and joining via multicomponent tungsten powder injection molding

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