Piotter, V.

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KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Micromoulding ofMetals and CeramicsKarlsruhe Institute of Technology (KIT)Institute for Applied Materials (IAM – WPT)Dr. V. Piotter   01.2012V. Piotter2KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Contents- Introduction Powder Injection Moulding (PIM)Micro Powder Injection Moulding (MicroPIM)- 2-Component Micro Powder Injection Moulding (2C-MicroPIM)- material/functional combinations- fixed connections- movable connections- Micro Inmould-labelling using PIM-Feedstocks- OutlookDr. V. Piotter    01.20123KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Dr. V. Piotter   01.2012Common materials in MSTTPEABSHousings for hearing aidsNanologic, PortugalSi-single chrystalIBMSi-waferNi, Ni-all.4KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Dr. V. Piotter   01.2012... and what about steelsand ceramics ?mechanics: forces, momentums, abrasionchemistry/analytics: corrosion, temperaturetelecommunication: thermal expansionfunctional materials: conductivity, PZT etc.KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Dr. V. Piotter   01.2012Options for manufacturing metal and ceramic micro partsbroad range of materialshigh economic efficiencyvarious design options}replicative additive subtractivee. g. e.g. laser-sintering micromechanical processes(milling, drilling, EDM etc)galvanoformingelectrophoresismetal castingpowder technologypowder injection moulding (MicroPIM)metal (MicroMIM)ceramic (MicroCIM)powder pressing6KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Dr. V. Piotter   01.2012FeedstockpreparationPowder    BinderShaping by(micro) injectionmoldingDebindingand sinteringSinter shrinkage(15 – 23 % linear)depending on powder/bindermixing ratioPowder Injection Moulding (PIM)17- 4PH7KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Dr. V. Piotter   01.2012PIM-Materials (selection)Mo-Al2O3, Fe-TiCcermets21 NiCr Mo 2, 16 MnCr 5case-hardened steelPZT, TiNfunctional ceramicsSi3N4, SiC, AlNnonoxide-ceramicsAl2O3, ZrO2, ZTA, ATZoxide-ceramicsCeramicWCxCo, TiNcarbides, nitridesHard metals,CermetsW, W-La2O3, WNiFe, WCu10, MoNb13, Mo20Curefractory metalsNiCr 22 Fe 18 Mo, NiCr 20 Co 18 Tinickel-base alloysTi6Al4V, TiAl7NbtitaniumCu, CuNi50, CuFecopperFe 29Ni 17Cocovarcarbonyl-Fe, Fe50Ni, FeSi3softmagnetic materialsFe2Ni, FeNi7low-alloyed ironX5 CrNiCuNb 17 4 (17-4PH, 1.4542)precipitation hardening steelX2 CrNiMo 17 13 2 (316L, 1.4404)austenitic stainless steelX20 Cr 13, X6 Cr 17stainless steel100 6W 5Mo 4 Cr 2Vtool steel42 CrMo 4, 40 NiCrMo 6 tempering steelMetal8KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Dr. V. Piotter   01.2012PIM – industrial applicationsBernhard Förster GmbHKrone GmbHworldwide market MIM: ~ 1.000 Mio. US-$CIM: ~    400 Mio. US-$Maxxon Motor GmbH9KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Dr. V. Piotter   01.2012Contrary demands on MicroPIM powdersMicroPIM - Feedstockscontour details and surfacequality:powder size as fine aspossiblegood flowability and lowsintering shrinkage:powder size as large as possiblecurrent compromise: particle sizes between 0.2 µm (ceramic) – 4 µm (steel)Solutions:- optimized additions of dispersants- multimodal mixtures of nano- and micropowders↔10KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Dr. V. Piotter   01.2012Binder optimization using tailored dispersants(2, 10, 20, 100)Brij 72,76,78,700Sigma AldrichGlycol, polarPE, unpolarreduced glycole chain length leads to lower energy input and viscosity=>  increased powder content ( ≥ 50 Vol.%)• optimized dispersant content11KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Increasing powder content by using bimodal powdersMicroPIM - Feedstocks• bimodal: 60 vol.% powder content ( 70 % rough + 30 % fine)• monomodal: 50 vol.% powder content (100 % rough)Increasing the powder content from 50 → 60 vol.% whileprocessibility and viscosity remain equalT=160 °CDr. V. Piotter   01.201212KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Dr. V. Piotter    01.2012Closing + Heating of mold corePlastification of feedstockEvacuation of moulding toolInjection of feedstockDwell pressure phaseCooling of moulding toolPrecise tool movementsEjection and handlingSpecialitiesHeating / Cooling = Variotherm-processnecessary for replication of high aspect ratiosInjection Moulding of Micro Components13KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)MicroPIM - DebindingR. GermanSan Diego SUExtraction of the organic binderat KIT approved for MicroPIM:solvent pre-debindingthermal main debinding~ 500°CDr. V. Piotter   01.201214KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Dr. V. Piotter   01.2012MicroPIM - Sinteringthermal debinding and sintering process63Vol.% powder, 17-4PH, H2-atmosphere densities of up to 96 – 99% of theo. density achieved generation of fine grain sizes by optimized heating- and cooling rates15KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Dr. V. Piotter   01.2012MicroPIMCeramic gear wheelouter-∅ approx. 275 µm130 µmMicro gear wheel made of steel17-4PH, outer-Ø = 610µmEPMA Award 2008 to ParmacoMetal Injection Molding AG, CHCapillary for fine pitch bondingtip-Ø=45µm, hole-Ø=19µmSPT Roth Ltd., CH16KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Dr. V. Piotter    01.2012Injection Moulding of Micro Components15>1025Aspectratio[grooves]± 0.3***< ± 0.5± 0.05Tolerance[%]<15>10>20 (200*)Aspectratio[isolatedwalls]2  /  <0.37  /  0.80.05  / <0.05Roughness ** Rmax /  Ra[µm] 1300<3<10Ceramics13001050Metals2500<0.110Plasticsmax. Height[µm]min.Detail[µm]min. lat. Dimension[µm]Materials* flow length to wall thickness ratio          ** depending on mould insert*** down to ± 0.1% under certain conditionsMicro Injection Moulding – General Data17KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Multi-Component Parts Produced by MicroPIMFunctions integration by combining different materialsRealization of (im-)mobile connectionsReduction of handling and assembly expenditureMulti-Component Micro Powder Injection MouldingObjectivessingle-piece fabrication+ assembly2C-MicroPIM– assemblyDr. V. Piotter    01.201218KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)2C-MicroPIM – Mobile + Immobile ConnectionsBasic RulesThermal expansionnearly equalSinter temperaturenearly equalPowder loadingcompatibleBinder systemImmobileMobilenearly equalalmost equalinner section < outer sectioninner section < outer sectionn.  r.Dr. V. Piotter    01.201219KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)2-component PIMHard metal WCxCo with differentCo-contents (16% and 6%), ARBURG 2-componenten MIM, AMT, SingaporeFraunhofer Institute, IFAMDr. V. Piotter    01.2012Combination of a magnetic steel (17-4PH, 1.4542) with a non-magnetic steel (316L, 1.4404)20KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)2C-MicroCIMFeedstock 1 Feedstock 2TiN-content ↓Rspez ↑TiN-content ↑Rspez ↓Material: Al2O3/TiN-mixture, electrical conductivity according to TiN-contentDemonstrator: ceramic heating needleDr. V. Piotter    01.201221KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)2C-MicroCIMGreen bodylength = 22 mmcross section = 1 mm² Function test run of ceramic heating elementAdjustment of sintering shrinkage byvariation of powder contentDr. V. Piotter    01.201222KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Immovable connection of thermodynamically unmixable ceramicsRealization of movable connections2C-MicroPIMZrO2Al2O3Dr. V. Piotter    01.2012Al2O3ZrO223KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)- combining the advantages of two shaping methods …Micro Powder Inmould-labelling (IML-MicroPIM)doctor bladetape castingfeedstocktapeEU Project  No. FP7-NMP4-2007-214122 Dr. V. Piotter    01.201224KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Micro Powder Inmould-labellingclosing + injectionopening + ejectionIML-toolµ-structured mould insertmetal orceramicfoil/filmPIM-Feedstock containing Powder 1foil/film containing Powder 2Powder 2:  functional or nano-particles applied on the structured surface better contour accuracy, higher surface quality,functional properties etc. Dr. V. Piotter    01.201225KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Micro Powder Inmould-labellingCurrent Results (ZrO2)tapeceramicfeedstockgreen bodygreen bodyDr. V. Piotter    01.2012sintered partformer boundary linetapefeedstock26KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)MicroPIM – Future Developments- Expanding the range of materialsfunctional materialsfine and nano powders etc.- Improvement of dimensional accuracy and surface quality- Enhanced multi-component process variantse.g. EU-Project „Multilayer“- Special Software for Simulation of MicroPIMOutlookDr. V. Piotter    01.201227KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)- Federal Ministry for Education and Research BMBF- European Commission- Deutsche Forschungsgemeinschaft DFG (SFB 499)- Companies Arburg, microParts, Wittmann Battenfeld, RKT, SPT Roth, Junghans, Inmatec etc.- State of Baden-Wuerttemberg- All colleagues at KIT  especiallyS. Antusch, W. Bauer, T. Hanemann, J. Haußelt, R. Heldele, J. Prokopand P. Holzer, E. Honza, T. Müller, K. Plewa, H. Walter and many othersThank you !AcknowledgmentMicromoulding of Metals and CeramicsDr. V. Piotter    01.2012

Micromoulding of metals and ceramics

https://publikationen.bibliothek.kit.edu/230086158/3816004

Micromoulding of metals and ceramics

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