How to choose Metal Injection Molding or Die Casting?

Actually there are so many similarities between Metal Injection Molding(MIM) and Die Casting, Both of these two metal parts producing methods take use of mould, and their producing process are sort of similar, melt metal injected into mold and forming, manufacturers always like take these two producing methods. Therefore, how to define if a metal components project is suitable for Metal Injection or Die Casting?

1.Raw Materials

Commonly used materials for

Die Casting: Aluminum Alloy, Magnesium Alloy, Zinc Alloy, and Copper Alloy in designated circumstance.

Metal Injection Molding: Varieties of Stainless Steels, Iron based.

If we dig deeper, we would find that the biggest diffence between Metal Injection Molding and Die Casting raw materials is melting point, as the melting point is higher of Metal Injection Molding, in Metal Injection Molding, the shape of raw materials is powder, and we would add binders into MIM process, and then sintering process, which is like “oven” process.

As Die Casting usually take formed materials, so we can see that Metal Injection Molding have higher raw materials requirements but more complicated producing process.

2.Size and Weight

The range of Die Casting size is much wider than Metal Injection Molding. It also means Metal Injection Molding have limitation in size nowadays, usually can produce metal parts under 200g.

For the product’s weight of these two manufacturing methods, due to the “binders” wouldn’t remove completely in MIM process, whereby the MIM components would be lighter. In the “lose weight” stream of many industies today, it’s an very important way to achive.

3.Quantity and Costing

Costing is always an important fector when choosing manufacuring process. While the quantity is always an important factor need to be consider. And both of Metal Injection Molding and Die Casting must make mold.

But in generally, when quantity is exceed one specific number, Metal Injection Molding would cheaper than Die Casting.

In any way, the best important reason to choose Metal Injection or Die Casting is raw materials, and specific individual requirements of each metal part project. Last but not the least, take consideration about the quantity for budget control.

ZCMIM, the advanced Metal Injection Molding Manufacturer in China, always offer the best choice for customers not just MIM.

Powder Metallurgy Technology Update

Powder metallurgy technology is a new energy saving and high efficiency technology. It plays an important role in economic development. In recent years, powder metallurgy products industry developed rapidly. Along with the update of technological change, development prospect for powder metallurgy industry is broader and broader. Powder metallurgy gear can be used in various hull pump parts, such as piston, filter, etc. Marine diesel engine parts can also be used powder metallurgy process.

Original article link：http://www.zcmim.com/article/powder-metallurgy-technology-pmtu_1.html

powder metallurgy state classification

Powder metallurgy technology in the application of the material, not only can be classified according to their state of aggregation, but also can be classified according to the degree of crushing and adhesiveness, particles separated between bai intermediate medium, in the dense metal, intergranular contacts within the entire volume to see see, powder material particles are often touch each other, but the nature of the contact between the solid grain and contact is different.

Original article link：http://www.zcmim.com/article/powder-metallurgy-technology-pmsc_1.html

Powder Metallurgy Technology pplication

In defense industry, such as launch vehicles, missiles, aircraft engines, ships, nuclear industry, military electronics industrial heat and corrosion resistance refractory metals, ultra hard materials, those can only be produced by powder metallurgy technology. In modern science technology, nanotechnology is also a new field of powder metallurgy. Therefore, powder metallurgy technology always gain world attention as a new high technology in field of material science.

http://www.zcmim.com/article/powder-metallurgy-technology-pp_1.html

powder injection molding process 6

powder injection molding process is using metal powder as raw materials, such as stainless steel, iron, low alloy steel, using powder metallurgy technology to manufacture various structural parts, powder metallurgy parts is with the mold, so parts of the contour and the consistency of shape and size are very good, by way of the binder removal sintering.

Steam treatment process in powder metallurgy process

In the powder metallurgy process, for it is refrigeration compressor steam treatment on the sealing process and increase the tightest, namely the powder metallurgy parts placed in a heating furnace at a certain temperature, certain amount to pass into the furnace in the supersaturated water vapor, in part around the existence of a large number of water vapor.

Those who come into contact with the surface of the steam iron atoms, including the outer surface and the inner surface of the connected voids occurs, oxidation reaction, generating a layer of oxide film, the main component of this layer of oxide film is Fe3O4, Fe3O4 is a body centered cubic system, the density of 5.16g/ cm3, the Fe3O4 of iron than the volume ratio, the internal parts of the connectivity gap closed, achieve the purpose of sealing parts, increase air tightness.

Due to the oxide film and cover in the parts of the substrate surface, very dense and strong adhesion, resulting in the environment of water vapor and corrosive medium is difficult to enter the parts inside, to reach a good anti rust function. Due to the high hardness of Fe3O4 and Rockwell hardness of pure Fe3O4 around 50HRC, processing parts of the apparent hardness reaches more than 60HRB, is helpful to improve the base parts surface hardness, wear resistance, anti abrasion, tensile strength can also be improved, steam treatment, the tensile strength of iron base materials increased 40-50%.

Advantages and characteristics of powder metallurgy materials

Materials fabricated by the powder metallurgy method are referred to as powder metallurgy materials (MetallurgyMaterials Powder). The so-called powder metallurgy, is the production of powder and consolidation (such as compaction and sintering) powder to prepare materials or parts of the technical process. At present, it is an effective means to improve the performance of household electrical appliances and the development of new materials.

1.1 powder metallurgy is an effective way to make special functional materials

The special functional materials prepared by powder metallurgy can be classified into 5 categories:

1) can control the porosity (such as filter, oil bearing, etc.).

2) can produce fake alloy composite materials (such as contacts, metals, diamond, etc.).

3) can produce refractory metals (such as tungsten, molybdenum wire, etc.).

4) can produce components of homogeneous materials (such as dispersion strengthened copper, powder high speed steel, etc.).

5) can produce special functional materials (such as light, sound, electrical integration of materials, etc.).

Powder metallurgy is the technology of material and energy saving, environmental protection, powder metallurgy process almost does not produce soot or chemical contamination, the near net shape manufacturing parts and less or no cutting, least scrap losses, coupled with the single light weight material utilization rate is the highest. A powder metallurgy material is used for the statistics of the same products. The cost was reduced by 75%, efficiency increased by 1.7 times. Therefore, performance of household appliances materials to increase or reduce the cost of home appliances using wood from the point of view, development and application of powder metallurgy materials in the home appliance industry is imperative under the situation.

Powder metallurgy materials for household appliances

Many household appliances will now used in powder metallurgy process to make, take the common electric fan, refrigerators, computers, air conditioning, but also with respect to the traditional process, used in powder metallurgy price and cost far below the traditional process, today Xiaobian accompany you to understand household appliances in powder metallurgy materials together!

In the development of household electrical appliances, the early stage of powder metallurgy is mainly made of copper based oil bearing bearing. Difficult parts, such as high precision, complex shape of compressor cylinder cover, cylinder liner, as well as some special performance requirements of the product also gradually developed. Our country just all kinds of compressor of powder metallurgy structural parts demand, such as air conditioners and refrigerators for rotary compressor, the annual output of about 355 million units, and each will need to powder metallurgy structural parts 80-350g.

Connecting rod type compressor for refrigerator and its annual output is about 827 million units, and each requires powder metallurgy structural parts 100g; sliding screw type compressor of air-conditioner and refrigerator, its annual output is about 310 million units, and each is need to powder metallurgy structural parts 30~200g. Household electric appliance is a big market of powder metallurgy structural parts, but these parts are not only complex in shape, but also require high temperature and high pressure. This is also very useful for powder metallurgy factory to further improve the level of technology and equipment and technical design.

In order to reduce the noise, has entered the household washing machine and an electric fan motor is used in powder metallurgy bearing, especially low noise, can substitute for copper in iron base oil bearing, the noise of the whole machine for ~ 40dB powder metallurgy oil bearing. Because of its self lubrication, low noise, cheap price, suitable for mass production, so it is widely used in the powder metallurgy oil bearings, such as cameras, tape recorders, etc..

Analysis of powder metallurgy technology and its application

The application of powder metallurgy technology in ancient times, the first method of making iron is essentially used in powder metallurgy. And the development of modern powder metallurgy technology, there are three important signs:

1, to overcome the difficulties produced in the process of refractory metal casting, in 1923 powdermetallurgy cemented carbide was hailed as a revolution in machining.

2, thirty years, the successful preparation of porous oil bearing; and then the development of powder metallurgy iron based machinery parts, and give full play to the advantages of powder metallurgy less cutting and cutting.

3, in the 1940s, metal ceramic, dispersion strengthened materials such as, from the late 1960s to early 1970s, high-speed steel powder, Powder Superalloy have appeared, and the powder metallurgy forging and hot pressing technology gradually large-scale manufacturing parts with complicated shape and high strength.

Advantages of powder metallurgy technology

1, the vast majority of refractory metals and compounds, pseudo alloys, porous materials can only be manufactured by powder metallurgy method.

2, due to the powder metallurgical method can be pressed into the final size of the compact, and do not need or need little subsequent mechanical processing, it can greatly save metal, reduce the cost of products.

3, due to the technology of powdermetallurgy in the production process of the material does not melt materials, not mixed with impurities caused by crucible and deoxidizing agent and sintering general in vacuum and in a reducing atmosphere, not afraid of oxidation nor to any material pollution.

4, powder metallurgy method can guarantee the accuracy and uniformity of the composition ratio of the material.

5, powder metallurgy is suitable for the production of the same shape and the number of products, especially gear and other high processing costs of products, powder metallurgy process can greatly reduce production costs.

What needs to use the powder metallurgy process?

At present, China's household electrical appliances has entered a stage of stable development, household appliances and materials quality is becoming increasingly important, especially widely used in household appliances, powder metallurgy process is particularly remarkable. Because some household appliances materials and parts can only be by the powder metallurgy method to manufacture, such as compressor refrigerator, washing machines, electric fans and other porous self-lubricating bearings;

some household appliances materials and parts with powder metallurgy method to produce better quality and lower prices, such as home air conditioner row fan and vacuum cleaners in the complex shape of the gear and the magnet etc.. In addition, powder metallurgy has important significance in maintaining the ecological environment, protecting the environment, saving energy and so on.

The application status of household appliances in powder metallurgy materials: according to the data, Taiwan powder metallurgy parts market distribution is as follows: car parts accounted for 19%, electric tools, accounted for 23%, household appliances account for 27%, mechanical parts accounted for l8%, sewing machine parts accounted for 13%. Obviously, the powder metallurgy materials used in home appliances have already possessed a large proportion, if combined with the domestic power tools and office machinery, its ratio is more considerable.

Powder metallurgy stainless steel structureparts have been widely used in home appliances. Such as 304L stainless steel powder metallurgy materials making parts for automatic dishwashers and washing machines, with 316L powder metallurgy materials making refrigerator ice maker launched disk, with 410L powder metallurgy material production limit switches and clutch etc.. Household dishwasher, clothes dryer, washing machines, sewing machines, vacuum cleaners, refrigerators, food mixer, gramophone, phonograph records, tape recorder, electric fans and other is also widely used in powder metallurgy copper based alloy.

Other applications of powder metallurgy materials

First, to provide special materials for manufacturing and defense industries. Manufacturing industry is the foundation of the sustainable development of the national economy. It is the engine and power source of industrialization and modernization. Powder metallurgy products in the manufacturing industry especially the equipment manufacturing industry in the use of high strength, high density of mechanical parts, hard alloy, electric contact materials, a variety of permanent magnetic and soft magnetic materials, sintered metal filter material, etc. more and more.

In the defense industry, such as launch vehicles, missiles, aircraft engines, ships, nuclear industry, the use of heat and corrosion resistance, refractory metals, ultra hard materials in the military electronics industry, etc.. Can only be produced by powder metallurgy technology. In the modern science and technology, nanotechnology is an emerging field of powder metallurgy. Therefore, in the world, powder metallurgy technology has been a new technology is paid more attention in the field of material science.

Second, another powder metallurgy technology is the main direction of development of manufacturing machinery parts. Including structural parts, oil bearing and sintered friction materials. Powder metallurgy parts starting in 1916, in the performance of copper based powder metallurgy bearing industry. With the development of automobile industry, powder metallurgy parts for automobile manufacturing industry.

In order to adapt to the car to environmental protection, energy conservation, reduce manufacturing cost and improve the performance requirements, people developed the automobile engine, gearbox and other used on thousands of key powder metallurgy parts, such as exhaust door seat, a connecting rod, a ABS ring, all kinds of gear, chain wheel, automatic variable speed device part, cam. Powder metallurgy technology has become the automobile and auto parts manufacturing industry to improve and enhance the quality and development of new materials, new products, reduce production cost and enhance the competitive ability is one of the key technology. The global auto industry has been paid much attention.

Why is the metal part of the metal powder injection molding injection molding it?

Metal powder injection molding (MIM) is a new type of powder metallurgy near net forming technology which combines the modern plastic injection molding technology with the traditional powder metallurgy technology. MIM products with high dimensional accuracy (+ 0.1% ~ + 0.5%), good surface finish (roughness 1 ~ 5 m), and the yield is very large. But the MIM process is more, there are certain technical barriers. Why MIM can't do a mobile phone in the frame structure / back cover larger?

First of all, MIM debinding and sintering will make the product size, product size, size deviation is larger, and not easy to skim;

Secondly, the majority of MIM stainless steel parts, although stainless steel anode, but still aluminum anode effect best (mainly because of the aluminum oxide layer by alumina composition, the formation of well ordered hexagonal tube structure, similar to the specular reflection effect, the color looks bright.

Nevertheless, there are still companies try to use MIM technology in the mobile phone / box cover, is the MIM technology to further tap! In general, at present, processing machine represents the phone boxes / cover in the high-end market; stamping represents a phone box / cover in the low-end market, the mainstream of MIM on behalf of mobile phone small parts and other metal parts.

Historical origin of Damascus steel powder metallurgy!

Is the so-called "mountains multiply and streams double back no doubt, There is a way out". In the late twentieth Century, the powder metallurgy technology, which developed in Sweden, has brought a new turning point for Damascus steel.

From 1992 to 1995, the Swedish Erasteel in powder injection forming steel production process, increase the parting a powder equipment, so that two kinds of steel powder by the sub equipment according to layers of lined up for the next step of high temperature and high pressure welding process, the formation of parallel lines of powder metallurgy Damascus steel. Modern steelmaking technology can make chemical elements to achieve the best ratio, but this technology is not perfect. Traditional method of steelmaking in the steelmaking furnace to molten steel by blowing argon treatment, vacuum degassing, desulphurization, directly into the sort of metal to the ratio of the required a variety of elements, and then enter the by refractory bricks or cement refractory made of ladle, by ladle into the mold cooling to obtain ingot.

In this process, the steel-making furnace in various chemical elements distribution is the most homogeneous ideal state, and after entering the ladle, temperature began to decrease, at this time of molten steel in the same components will happen aggregation, until into the mold to cool completely, aggregation phenomenon is more serious, strict composition is far less than the in furnace even when the. There is a saying that "the furnace is gold, the bag is silver, cooling is the stone", that is, the meaning of.

In theory, the use of powder metallurgy to produce Damascus steel, you can choose the world's two kinds of steel fusion, but the actual operation is also a grasp of. The choice of the original steel generally consider the following factors:

Performance complementation -- the composition match should be satisfied with a particular application; heat treatment parameters - two kinds of steel should have the same or similar heat treatment process parameters;

Thermal effect - two steel due to the same or similar thermal effect, in order to ensure the forging and heat treatment does not affect the performance of the steel; corrosion patterns of two types of steel elements in at least one has enough differences to ensure the clearness of the lines.

What are the requirements of powder metallurgy technology?

Powder metallurgy technology can easily realize multiple types of composite, give full play to the characteristics of each element of the respective materials, is a technology for the production of high performance metal matrix and ceramic composite materials with low cost. So what are the requirements of powder metallurgy technology?

1, powder metallurgy technology can minimize the alloy composition segregation, eliminating coarse and uneven casting organization.

2, powder metallurgy technology can be prepared in amorphous and microcrystalline, crystal, nano crystal and super saturated solid solution and a series of high performance non equilibrium materials. These materials have excellent electrical, magnetic, optical and mechanical properties.

3, powder metallurgy technology can realize the near net shape forming and automatic batch production, which can effectively reduce the production of resources and energy consumption.

4, powder metallurgy technology can produce ordinary smelting method can produce with special structure and properties of materials and products, such as a new type of porous biomaterials, porous separation membrane materials, high performance structure ceramic abrasive and ceramic materials and other.

5, powder metallurgy technology can make full use of ore, tailings, steelmaking sludge, steel rolling mill scale, recycling of scrap metal as raw materials, is a kind of new technology can effectively carry out the material recycling and comprehensive utilization.

Powder metallurgy metal has a unique chemical composition and mechanical and physical properties, and these properties is conventionally casting method can not be obtained. The powder metallurgy technology can be directly made into porous, semi dense or fully dense materials and products, such as oil bearing, gear, cam, guide rod, cutter, etc.

What are the main functions of powder metallurgy technology?

The powder metallurgy technology can be directly made into porous, semi dense or fully dense materials and products, such as oil bearing, gear, cam, guide rod, cutter, etc..

(1) powder metallurgy technology can reduce the segregation of alloy components and eliminate the coarse and uneven casting structure. In the preparation of high performance rare earth permanent magnetic materials, rare earth storage hydrogen materials, rare earth luminescent materials, rare earth catalyst, high temperature superconducting materials, a new type of metal materials (such as Al Li alloy, heat-resistant Al alloy, super alloy, powder corrosion resistance of stainless steel, high-speed steel powder, intermetallic compounds for high temperature structural materials) has an important role.

(2) can be prepared in amorphous and microcrystalline, crystal, nano crystal and super saturated solid solution and a series of high performance non equilibrium materials. These materials have excellent electrical, magnetic, optical and mechanical properties.

(3) it is easy to implement various types of composite, give full play to the characteristics of each component, and it is a kind of low cost technology for producing high performance metal matrix and ceramic composite materials.

(4) can produce ordinary smelting method can produce with special structure and properties of materials and products, such as a new type of porous biomaterials, porous separation membrane materials, high performance structure ceramic abrasive and ceramic materials and other.

(5) can achieve near net shape forming and automated mass production, so that can effectively reduce the production of resources and energy consumption.

(6) it can make full use of ore, tailings, steel making sludge, steel rolling scale, recycling of scrap metal as raw materials, is a kind of new technology which can effectively carry out the material recycling and comprehensive utilization.

All the above are the characteristics of powder metallurgy, powder metallurgy technology has significant energy saving, material saving, excellent performance, high precision and good stability, and a series of advantages, is very suitable for mass production.

Problems to be noticed in mechanical polishing

Should pay attention to problems in mechanical polishing with sandpaper polishing, should pay attention to the following points:

(1) need to use sandpaper polishing stick or soft bamboo stick. When polishing round or spherical surface, the use of cork rod can better fit the circular surface and the surface of the sphere. Hard wood like cherry, polishing is more suitable for smooth surface. Trimming of the wood at the end of the surface shape of steel parts and kept consistent. Only in this way can avoid the wood or bamboo strips) acute angle of contact on the surface of steel caused by deep scratches.

(2) when used for different types of sand paper, the polishing direction should transform 45 ~ 90 degrees, so the former models of sandpaper polishing after leave the shadow stripe can be resolution. Before the change of different types of sand must be 100% pure cotton picks up like alcohol cleaning fluid to the polished surface was carefully wipe, because that will destroy the next a small gravel left on the surface polishing work as a whole. From the sandpaper polished into diamond grinding paste polishing, the cleaning process is equally important. All particles and kerosene must be thoroughly cleaned before the polishing is carried out.

(3) in order to avoid scratches and burn the surface of the workpiece, must be careful in using #1200 and #1500 sandpaper polishing. So it is necessary to load a light load and use the two step polishing method to polish the surface. For each type of sandpaper polishing should be in two different directions of two polishing, two direction between each rotation of 45 degrees ~ 90 degrees.

What are the properties used for the determination of powder metallurgy?

What are the general characteristics of the powder used for powder metallurgy?

There are three general: chemical composition, physical properties and process performance. The physical properties of the powder used for powder metallurgy mainly include those?

(1) particle shape of powder;

(2) the size and composition of the powder;

(3) the specific surface of the powder.

What are the main properties of powder metallurgy process for powder metallurgy? Mainly include the following five:

(1) loose packing density;

(2) the density of vibration:

(3) liquidity;

(4) compressibility;

(5) formability.

In recent years, the average annual growth rate of powder metallurgy products in China is over 15%

A lot of metal forming processes are closely related to the development of materials and powder metallurgy. Powder metallurgy is the process of metal powder as raw material, through the forming and consolidation, the manufacture of metal materials, composite materials and products. The development and production of high performance metal powder plays an important role in improving the properties of powder metallurgy materials and products and promoting the progress of powder metallurgy technology.

In all kinds of metal powder, high purity iron powder is powder injection molding is an important one of the raw materials, consumption accounts for about the powder metallurgy industry with 70% of the amount of powder, which reduced iron powder due to having a porous, with irregular morphology, forming and good green strength is high pressure, in divided into auto parts, compressor parts, sintered bearing, electric tool parts and electronic components production become irreplaceable raw materials.

Statistics show that in the last 5 years, the average annual growth rate of China's powder metallurgy products is 15.4%, the average annual growth rate of sales revenue is 16.2%. In 2013, the total sales volume of powder metallurgical machinery parts in China has reached more than.

Present situation and market demand of powder metallurgy technology at home and abroad

According to the China General Machinery Parts Association powder metallurgy branch report, 2006 China's powder metallurgy parts and products production increased by 17.5%, reaching about 88000t. Statistical product categories include iron copper based powder metallurgy parts, oil bearing and friction materials. In which the amount of powder metallurgy parts of the automobile market is about 32000t, accounting for 37%, an increase of 28%; power tool market growth of 29%.

The future will show a potential of China's automobile parts in powder metallurgy products market growth spurt. According to statistics, the amount of powder metallurgical products in developed countries accounted for the vast majority of the total production of powder metallurgy products, such as the United States accounted for 90%, 80% in Europe, while China is still less than 40%. European average per vehicle powder metallurgy products usage is 14kg, Japan is 16KG, the United States has reached more than 19.5kg.

The next few years is expected to reach 22kg, while China's current average per vehicle powder metallurgy products are only about 5kg. If calculated according to an annual output of 50 million cars, China's annual auto parts uses about 2.5 million tons of iron and steel powder, if the amount of our country every car powder metallurgy products to reach the European level, and keep car powder metallurgy parts replacement, so only the steel powder will need to nearly 10 million tons, is 1.25 times as much as that of the powder metallurgy total demand.