Antusch, S.

Commin, L.

Müller, M.

Piotter, V.

Rieth, M.

Walter, H.

Weingärtner, T.

English

KITopen

KIT-IAM1 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012POWDER INJECTION MOLDING (PIM) –A MULTI-PUPOSE PROCESS FOR ARMOR PART FABRICATION AND MATERIALS DEVELOPMENTKarlsruhe Institute of Technology (KIT)Institute for Applied MaterialsMaterial Process TechnologySteffen Antusch, Lorelei Commin, Marcus Müller, Volker Piotter, Michael Rieth, Heinz Walter, Tobias WeingärtnerUniversity of Oxford  May 30, 2012KIT-IAM2 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012• Motivation• What is Powder Injection Molding (PIM)?• The PIM process for tungsten developed at KIT• Material development for PIM• Producing of 2-Component W PIM divertor parts• Summary & OutlookOutlineKIT-IAM3 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012• Motivation• What is Powder Injection Molding (PIM)?• The PIM process for tungsten developed at KIT• Material development for PIM• Producing of 2-Component W PIM divertor parts• Summary & OutlookKIT-IAM4 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Future fusion power reactor DEMOMotivationOne promising divertor design – developed at KITP. Norajitra et al., KIT. KIT-IAM5 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012 1 Finger-mockup – 3 main parts 2 – 3 several materials 2 brazed joints assembling, adjustment… DEMO: nearly 300.000 mockups lifetime nearly 2 years Reasonable manufacturing method?MotivationKIT-IAM6 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012• Motivation• What is Powder Injection Molding (PIM)?• The PIM process for tungsten developed at KIT• Material development for PIM• Producing of 2-Component W PIM divertor parts• Summary & OutlookKIT-IAM7 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012What is Powder Injection Molding (PIM)?…manufacturing technology…KIT-IAM8 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012What is Powder Injection Molding (PIM)?…manufacturing technology…Feedstock Injection Molding tool Injection Molding machineGreen partsKIT-IAM9 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012What is Powder Injection Molding (PIM)?…manufacturing technology…Powder Injection Molding (PIM)Metal Injection Molding (MIM) Ceramic Injection Molding (CIM)KIT-IAM10 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Al2O3ZrO2Smallest ZrO2 gear wheel of the world: outer- 275 µm What is Powder Injection Molding (PIM)?…parts produced at KIT…CopperTungstenSteelTitaniumCeramicKIT-IAM11 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Advantages Cost-effective mass production Producing of 3D-parts Metal forming of tungsten based materials complicatedChallenges Adequate powders /  powder mixtures preparation / feedstock development Heat-treatment process High density Low porosityWhat is Powder Injection Molding (PIM)?…tungsten PIM…KIT-IAM12 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012• Motivation• What is Powder Injection Molding (PIM)?• The PIM process for tungsten developed at KIT• Material development for PIM• Producing of 2-Component W PIM divertor parts• Summary & OutlookKIT-IAM13 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012The PIM process for tungsten developed at KITKIT-IAM14 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012The PIM process for tungsten developed at KIT1. PowderSEM Microstructure tungsten powder W1 SEM Microstructure tungsten powder W2KIT-IAM15 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012The PIM process for tungsten developed at KIT2. Feedstock development - kneadingKIT-IAM16 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012The PIM process for tungsten developed at KIT…steps for developing of a new PIM tool…Needful knowledge about:- Powder properties (size, shape, surface,…)- Powder / Binder relationship- 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 improvementpretests +analyzes6 month6 month+KIT-IAM17 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012The PIM process for tungsten developed at KIT…filling simulation…Information aboutthe gating system:-position-sizeKIT-IAM18 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012The PIM process for tungsten developed at KIT…filling simulation…KIT-IAM19 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012The PIM process for tungsten developed at KIT…The divertor W PIM part „tile“…KIT-IAM20 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012The PIM process for tungsten developed at KITKIT-IAM21 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012The PIM process for tungsten developed at KIT…Injection Molding of green parts…KIT-IAM22 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012The PIM process for tungsten developed at KITgreen parts finished partsdebinding +heat-treatment-processKIT-IAM23 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012The PIM process for tungsten developed at KIT…Heat-treatment process…KIT-IAM24 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Density >95% - closed porosity!!!Vickers-hardness 420 HV0.1The PIM process for tungsten developed at KIT…Heat-treatment process…S. Antusch et al., J. Nucl. Mater. 417 (2011) 533-535. only pre-sintering pre-sintering + HIPDensity >98%Vickers-hardness 457 HV0.1SEM Microstructure pre-sintering W SEM Microstructure pre-sintering +HIP WKIT-IAM25 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012The PIM process for tungsten developed at KIT…Tungsten PIM samples…Green parts (dark) and finished parts (bright)KIT-IAM26 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012SEM image of the fracture surface: no porosity or cracksHeat-treatment process: - pre-sintering (1800 °C, 2 h, H2) + - HIP (2100 °C, 3 h, Ar, 250 MPa)Properties of the finished material:Vickers-hardness: 457 HV0.1Density: 98.6 – 99 % TDThe PIM process for tungsten developed at KIT…The divertor W PIM part „tile“…S. Antusch et al., Fusion Engineering and Design, 86 (2011) 1575-1578. KIT-IAM27 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012 Fabrication of the W PIM tile successful Joining via brazing of W PIM tile and W-alloy thimble (produced by mechanical machining)The PIM process for tungsten developed at KIT…joining… Mass production process? Courtesy of L. Spatafora (Bachelor Thesis 2010) KIT-IAM28 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012• Motivation• What is PIM?• The PIM process for tungsten developed at KIT• Material development for PIM• Producing of 2-Component W PIM divertor parts• Summary & OutlookKIT-IAM29 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012 Material produced by mechanical alloying (2 h, n-Hexane, ZrO2 balls + bowl) W-2La2O3 W-2Y2O3Mill and equipment grinding bowlgrinding ballsMaterial development for PIMPIM parts (small discs) producedHeat-treatment:- pre-sintering (1800 °C, 2 h, H2) +- HIP (2100 °C, 3 h, Ar, 250 MPa)Material Theoretical density (% TD) Vickers-hardness (HV0.1) Grain size (µm)W 98.6 - 99.0 457 5 - 7W-2La2O3 96.5 - 97.2 586 >3W-2Y2O3 96.3 - 97.1 617 <3KIT-IAM30 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012 W-2La2O3SEM Microstructure (fracture surface) SEM Microstructure (metallographic section)A selection of La2O3-particles is marked by arrows...Material development for PIMKIT-IAM31 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012 W-2Y2O3SEM Microstructure (fracture surface) SEM Microstructure (metallographic section)A selection of Y2O3-particles is marked by arrows...Material development for PIMKIT-IAM32 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012• Motivation• What is PIM?• The PIM process for tungsten developed at KIT• Material development for PIM• Producing of 2-Component W PIM divertor parts• Summary & OutlookKIT-IAM33 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Producing of 2-Component W PIM divertor partsS. Antusch et al., Fusion Science and Technology (2012) submitted. Pretests via insert 2-Component PIM:   W + W-2La2O3 / W + W-2Y2O3 PIM samples produced + characterized Heat-treatment:- pre-sintering (1800 °C, 2 h, H2) +- HIP (2100 °C, 3 h, Ar, 250 MPa)Material produced by mechanical alloyingKIT-IAM34 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Pretests via insert 2-Component PIM: W + W-2La2O3 Joining seam: without cracks or gaps  Material connecting successful black: La2O3red: WSEM Microstructure (fracture surface) AES Map (metallographic section)Producing of 2-Component W PIM divertor partsKIT-IAM35 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Pretests via insert 2-Component PIM: W + W-2Y2O3 Joining seam: without cracks or gaps  Material connecting successful black: Y2O3red: WSEM Microstructure (fracture surface) AES Map (metallographic section)Producing of 2-Component W PIM divertor partsKIT-IAM36 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012 Design and Engineering of a fully automatic2-Component PIM tool Tile and thimble in one unit with / without joining layer Joining of 2 different materials without brazing in 1 process stepKnowledge transfer –from pretests to real 2-Component Powder Injection Molding process: material combination, heat-treatment process, shrinkage, filling simulation…W PIM parts – material development – insert 2-C PIM pretests Goals:Producing of 2-Component W PIM divertor partsKIT-IAM37 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Nozzle sideEjection sideProducing of 2-Component W PIM divertor parts…The new fully automatic 2-C-W-PIM tool…KIT-IAM38 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Producing of 2-Component W PIM divertor partsKIT-IAM39 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Producing of 2-Component W PIM divertor parts…first samples…KIT-IAM40 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Producing of 2-Component W PIM divertor parts…first samples…W + W2La2O3Only presintering!AES Mapblack: La2O3red: WS. Antusch et al., J. Nucl. Mater. (2012) submitted. KIT-IAM41 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Producing of 2-Component W PIM divertor parts…first samples…W + W2Y2O3Only presintering!AES Mapblack: Y2O3red: WKIT-IAM42 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012• Motivation• What is PIM?• The PIM process for tungsten developed at KIT• Material development for PIM• Producing of 2-Component W PIM divertor parts• Summary & OutlookKIT-IAM43 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Summary• Material & process development for W PIM at KIT• Development of a suitable W feedstock: W1 + W2 (50:50) 50 vol.%• Optimization of the heat-treatment process: pre-sintering + HIP• Producing of W PIM parts Properties of the finished divertor part W tile: Density: 98.6 – 99 % T.D. Vickers-hardness: 457 HV0.1 Microstructure without porosity or cracks• Development of new W PIM materials:W-2La2O3W-2Y2O3• Pretests via insert 2-Component W PIM / Investigation of the joining zone quality: Joining seam: without cracks or gaps Material connecting successful• Design & Engineering of a new fully automatic 2-Component W PIM tool: First 2-Component W PIM divertor parts successful produced!KIT-IAM44 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012SummaryPowder Injection Molding:Mass production & joining processTime & cost effective near-net-shape forming processShape complexity and high final densityCreate new materials / Investigation of propertiesKIT-IAM45 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Outlook• Options of scientific cooperation: 4 point bending tests Structure analysis: FIB, SEM, EBSDMaterial characterization:- Charpy tests (KIT)- Tensile tests (KIT)- High Heat Flux Tests (IPP Garching, FZ Jülich)Material development, e.g.:- W-2Y2O3: mixing only- W-2Y2O3: mixing + MA 24h- W-2Y2O3: mixing + MA 48h- …other possible material combinations…Producing of PIM plates:W-PIM plate (55 x 22 x 4 mm)KIT-IAM46 Steffen Antusch – POWDER INJECTION MOLDING (PIM) 12.06.2012Thank you very much!

Powder injection molding (PIM) - a multi-purpose process for armor part fabrication and materials development

https://publikationen.bibliothek.kit.edu/230086969/3816053

Powder injection molding (PIM) - a multi-purpose process for armor part fabrication and materials development

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