Honza, E.

Klein, A.

Mueller, T.

Piotter, V.

Plewa, K.

English

KITopen

KIT – Universität des Landes Baden-Württemberg undnationales Forschungszentrum in der Helmholtz-GemeinschaftINSTITUTE FOR APPLIED MATERIALS  - (IAM – WK)www.kit.eduExaminations on Precision Powder Injection MoldingV. Piotter, E. Honza, A. Klein, T. Mueller, K.Plewa2 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Contents- PIM Accuracy: Powder loading- Thickness variations: Demonstrator- Minimum membrane thickness- Accuracy investigations- OutlookParmaco AG, Switzerland3 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Scheme of twin-piston toolcavityejector side dye sideinclined planeservomotor forpistonmovementpistonsinjection gates4 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)PIM  Accuracygate position: dye side / middlepiston pressure: 5.8% / 19.5%  of Pmax, motormeasuring positionsPowder:         17-4PH   Osprey 1.4542D50 ca. 4µmFeedstocks:First demonstrator:Cylinder Ø = 2.015mm5 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Green bodiesPIM  Accuracy6 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Sintered partsPIM  Accuracy7 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Parts with considerable thickness variationz=0,8mm	/	0,5mmz=1,8mm	/	1,3mm	z=2,8mm	/	2,1mmz=3,8mm	/	2,9mmz=4,8mm	/	3,7mmCreation of demonstrator:Membrane carrierbulk cylindermembrane8 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Process conductProcess 1: Unaltered powder injection molding- 63Vol% 17-4PH feedstock- filling simulations- constancy of cylinder diameter9 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Filling simulationverified by short-shot studiesEvaluation of most suitable runner system10 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Filling simulationdetermination ofcritical shear rates→ acceptableshear rates11 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Accuracy of unaltered PIMz=0,8mm	/	0,5mmz=1,8mm	/	1,3mm	z=2,8mm	/	2,1mmz=3,8mm	/	2,9mmz=4,8mm	/	3,7mmVariance ofcylinder diameterca. ± 0.15%12 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Process conductProcess 1: Unaltered powder injection molding- 63Vol% 17-4PH feedstock- filling simulations- constancy of cylinder diameter ca. ± 0.15% - minimum membrane thickness ca. 400µmProcess 2: Powder injection molding + embossing step»  pull back the pistons» filling this cavity by injection of feedstock» push the pistons forward up to final membrane thickness13 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)14 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Minimum membrane thicknessReduction of membrane thickness due to PIM + embossing processVariation of main parameters: embossing force, gap width,and embossing delay timeClassification (from 1 to 5) of molded membrane carriersClass 1 sample: no visible failures Class 5 sample: clearly visible voids15 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Thermal treatmentmembrane carriers before debindingMinimum membrane thickness≤ 200µmclass 1 sample after sinteringConstancy membrane thickness± 0.4%16 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Further reduction of membrane thickness200µm 150µm 100µmSintered samplethickness ca. 90µmfeedstock sticks on piston top17 Dr. V. Piotter 18.05.2015KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)PIM + embossing process- increase powder loading → 67Vol%- improve powder composition (bi-modal)- improve piston movement- avoid feedstock-wall adhesionOutlookSimulation of PIM- jetting, powder-binder segregation etc. - simulation of embossing step ↔ powder pressing18 Dr. V. Piotter 18.05.2015KIT – 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, SPT Roth, Sigma Engineering, Junghans, OBE etc.- State of Baden-Wuerttemberg- Fraunhofer Institutes IKTS and IFAM- All colleagues at KITThank you !Acknowledgment

Examinations on precision powder injection molding

https://publikationen.bibliothek.kit.edu/230100843/3816824

Examinations on precision powder injection molding

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