Shenzhen Metal Injection Molding Manufacturer Analyze MIM Powders

There are two main types of MIM injection molding powders. They are water atomized powders and gas atomized powders.  Following analysis of the composition and morphology  for those two powders are from a Shenzhen MIM injection molding manufacturer ZCMIM .

Water Atomised  powders for Metal Injection Molding MIM

l   Irregular shape

l   High proportion of oxide particles/impurites

l   Thick oxide layer, rich in SiO2

l   Low packing density

Gas Atomised powders  for Metal Injection Molding MIM

l   Regular, spherical shape

l   Low proportion of oxide particles/impurites

l   Thin oxide layer, typically ~2nm

l   High packing density ~65% theoretical  max

Through production practice and application of SIM card to discuss feedstock quality standards for metal injection molding

Feedstock series

Stainless steel, carbide, tungsten alloy, iron base

Feedstock quality standard

1.       Flow rate
In production of complex shape, thin wall parts, high flow rate could avoid air bubbles ,flow lines and not full filling during filling cavity. And can realize multiple-cavity, reduce equipment investment

2.       Injection cold feeding

3.       blank appearance

4.       blank  strength

5.       Number of repeat use 

Improve the reuse frequency can effectively reduce production cost. But as binder volatilizes  as  feedstock cycling for a long time, it  will reduce the flow rate of feedstock and  make  change for  blank filling compactness.

6.  Debinding efficiency

7.   Billet strength

8.  Sintering efficiency

9.  Sintering stability

10. Finished product density

11.Finished product appearance

Affecting Factors for MIM Products Size

Compared to machining, powder metallurgy PM process and casting process, accuracy performance is not its advantage of  metal injection molding MIM process. So what factors do exactly affecting size of MIM products? Shenzhen powder metallurgy factory –ZCMIM has made the following analysis based on years of stainless steel powder metallurgy experience and researches about metal injection molding industry:

Affecting Factors of metal injection molding MIM products size:
1. MIM mold size and its tolerance
2. Abrasion of  MIM mould
3. Matching error between moving parts of MIM mold
4. The structure of metal injection molding products
5. Weight deviation of metal injection molding product  in weight equal circumstances, the lower the density,  the larger size)
6.  Density deviation of MIM parts ( in density equal circumstances , the greater the weight, the larger the size)

China metal injection molding（MIM technology) main service communication products

Compared with the traditional process, Metal injection molding (MIM process) have characteristics of high precision and steady quality. Its products are widely used in electronic , information engineering, medical equipment, office equipment, automobile, machinery, hardware, watch industry, weapons and aerospace industry, etc.

Metal injection molding (MIM process) use thinner metal powder, can help to improve extend the fatigue life of materials. The current global scale of metal injection molding (MIM) industrial is still small, but grow in steadily. In Europe, its main application fields are cars. In North America, mainly in the medical field, Asia is mainly in the communication products.

The future development of metal injection molding (MIM) is mainly in terms of materials and design efforts. ZCMIM use of the advantages of the MIM process, provide the one-step for MIM products designing, production, surface treatment , to help customers improve product design and reduce the cost.

MIM technology promote the development of parts and components manufacturing industry

In recent years, the rapid development of economy promote the development of parts and components manufacturing industry. Metal injection molding（MIM） not only energy efficient but also can reduce pollution, save material, is the most advanced manufacturing technology. Metal injection molding（MIM） has an irreplaceable position and role in parts and components manufacturing.

Metal injection molding（MIM） parts of the theoretical density can achieve 95% above, through the reasonable technological parameters control can achieve 99.9%, close to full densification. And the MIM have technologies has the advantages of mass production of low cost and high degree of automation, is the most advanced powder metallurgy technology currently.

Metal injection molding（MIM） parts generally used in the manufacture of high strength and strong abrasion, also has a very wide range of uses in machinery, electronics, medical equipment, in automotive, electrical, agricultural machinery, motor also has a lot of uses.

The new technology of Powder metallurgy technology - metal injection molding（MIM）, will promote the development of the parts and components manufacturing industry, also will bring a bright road of spare parts for the future.

What is the main material of Metal injection molding?

Metal injection molding（MIM） is a very widely application of metal parts production technology, What is the main material of Metal injection molding? Follow ZCMIM to learn about:

There are wide applicable materials suitable for Metal injection molding technology, mainly includes: stainless steel, iron-based( nickel-based alloy), tungsten alloy, hard alloy, low alloy steel, tool steel, magnetic materials, etc.

ZCMIM is specialized in development, manufacturer and sales of Metal injection molding product using Metal injection molding (MIM) with Metal injection molding product materials including iron base, stainless steel (stainless steel 316 L, stainless steel 17-4 PH, stainless steel 304, stainless steel 440 C), iron (Fe -2Ni and Fe-8ni), hard alloy, high density tungsten alloy.

How to improve precision performance of metal injection molding MIM products

Making full assessment with customers in development stage of MIM project ,and formulate reasonable drawing requirement

Ø   MIM products tolerance as wide as possible

Ø  maximum optimize the structure of injection molding products

Ø  obligate necessary machining allowance in  MIM process

Revising precision metal injection molding size

Ø  Revising MIM mould manufacturing deviation

Ø  Revising MIM die designing deviation

Ø  Revising size changes caused by mould abrasion

  Accurate control the unit weight of  injection molding products

Ø  the repeat precision of injection molding machine

Ø  stability control of powder metallurgy molding conditions

Ø  consistency of powder metallurgy feedstock

Contrast for MIM and Traditional Process

  Metal injection molding(MIM) is a kind of "near net shape manufacturing process", used to produce MIM parts and CIM parts. It is a blend of two kinds of traditional process (plastic injection molding and powder metallurgy).

Contrast for MIM and Traditional Process
Item	Metal Injection Mold(MIM）	PM	Precision Casting	Machining Operation	Stamping
Density	98%	86%	98%	100%	100%
Tensile  Strength	High	Low	High	High	High
Surface Finish	High	Medium	Medium	High	High
Small size	High	Medium	Low	Medium	High
Thickness	High	Medium	Medium	Low	High
Complexity Level	High	Low	Medium	High	Low
Design Tolerance	High	Medium	Medium	Medium	Low
Capacity	High	High	Medium	Medium-High	High

Compared with metal injection molding and other molding technology

MIM(metal injection molding) is a small or no cutting process(also called near net-shape). Compared with traditional casting technology, the advantages of MIM as following:

1.    High surface smoothness, newest data from ZCMIM is surface R1.6 at lowest 

2.    Small tolerance and high precision dimension. Current domestic metal injection molding manufacture ZCMIM can do tolerance within 0.03mm~0.05mm. Some items can do with lower tolerance after post treatment.

3.    It is possible to prepare alloy materials and composite materials

4.    Good stability(no stand hole and shrink hole) and reliable mechanics performance

5.    Low energy consumption

The advantages of PM（powder metallurgy）

PM（powder metallurgy） has important position in metal parts manufacturing,and powder metallurgy has obvious advantages for products molding. Let's follow ZCMIM to know the advantages of PM（powder metallurgy）！

1、PM（powder metallurgy）is a small or no cutting process(Near purification molding);

2、PM（powder metallurgy）is suitable for produce the same components in mass production;

3、PM（powder metallurgy）can manufacture the complicated components in small tolerance(such as gears, cam wheel and versatile components);

4、PM（powder metallurgy）no need or can shorten the precision processing of machine

5、PM（powder metallurgy can save the energy and material;

6、PM（powder metallurgy）can produce self-lubricating components.