Development Trend of MIM Technology

Metalpowder injection molding( referred to MIM) technology is a new near net forming powder metallurgy technology imported from modern plastic injection molding technology.

1. Representative iron base alloy will be developed toward large volume precision products and high quality structural components.

2. Make uniform microstructure and difficult to process high performance alloy.

3. Manufacture general compounded special alloy by enhancing density.

4. Manufacture non - uniform materials, non-crystalline ,  micro-crystal or metastable alloy.

5. Manufacture unique, non general form and composite parts.

Original article link：http://www.zcmim.com/article/mim-technology-dtomt_1.html

What is Release Agent?

Metal injection molding manufacturer(http://www.zcmim.com/help/leaveword.shtml) ZCMIM will explain what is releasing agent today. Release agent is a functional substance between mold and product, is a processing aids used to prevent product from bonding to mold and easy to release from mould. Due to the rapid development of die casting process, the amount of release agent is greatly improved. If there is a need to understand, please consult website www.zcmim.com for details.

Original article link：Metalinjection molding manufacturer

Powder Metallurgy Parts—Density

Metal injection molding process is a liquid molding process.The existence of binder guaranteed even distribution of powders, which eliminates uneven microstructure of blank, and make products reach to its theoretical density. Under normal circumstances, the density of the sintered products can only achieve 85% of theoretical density. Product’s density can increase product strength, toughness, ductility, electrical conductivity, thermal conductivity and improve magnetism.

Original article link：Metalinjection molding process

Development Trend of MIM Technology

Metalpowder injection molding( referred to MIM) technology is a new near net forming powder metallurgy technology imported from modern plastic injection molding technology.

1. Representative iron base alloy will be developed toward large volume precision products and high quality structural components.

2. Make uniform microstructure and difficult to process high performance alloy.

3. Manufacture general compounded special alloy by enhancing density.

4. Manufacture non - uniform materials, non-crystalline ,  micro-crystal or metastable alloy.

5. Manufacture unique, non general form and composite parts.

Original article link：http://www.zcmim.com/article/mim-technology-dtomt_1.html

Powder Metallurgy Parts—Performance

In pressing process, due to friction between mould and powder, powder and powder, make the pressure distribution not uniform, also led to un-uniform microstructure of blank, Powder metallurgy parts(http://www.zcmim.com/bymaterial.shtml) it will result in un-uniform shrinkage during sintering process. Therefore we had to reduce sintering temperature to reduce this effect, which make large porosity and less density, seriously affecting product Original article link： http://www.zcmim.com/article/powder-metallurgy-parts_1.html

Metal Injection Molding Process-advantage

Due to economy and technology advantages, metal injection molding process has been widely used in the military supplies and civilian goods. MIMmetal injection molding technology can make complex shape, high dimension and accuracy small parts. Along with the improvement of raw powder quality and mature and diversification of technology, as well as well equipment, its application will be more and more widely and product performance will be further improved accordingly, which will make metal injection molding process become the important process gradually.

Original article link：

http://www.zcmim.com/article/mim-metal-injection-molding-pa_1.html

Metal Injection Molding-binder

The first process for metal injection molding material process is to choose metal powder and binder conformance to MIM requirement. Then, under a certain temperature using appropriate method to mix powder and binder to make uniform feedstock, after granulating, injection moulding green part. The green parts can become dense final products after  debinding and sintering. MIM technology including product design, mold design, quality inspection, mixing, injection, debinding, sintering and post process.

Original article link：

http://www.zcmim.com/article/metal-injection-molding-b_1.html

Surface Treatment Technology - Chemical Methods

Chemical method for surface treatment in powder metallurgy process is using interaction of chemical substances to form a coating layer on the surface. This method is not current effect,. Its main method is:

(1)   chemical conversion treatment

In electrolyte solution, the interaction of chemical substance and product make product surface form a coating, which is called chemical conversion treatment.  Such as bluing, phosphating, passivation and chrome -pickle treatment.

(2) Chemical plating

In electrolyte solution, catalyzing product surface without external current, as a result of chemical reduction, some material was deposited on product’s surface to form coating, which is known as chemical plating. such as chemical nickel plating, electroless copper plating etc.

Original article link：

http://www.zcmim.com/article/powder-metallurgy-process-sttcm_1.html

Surface Treatment Technology - Electrochemical Method

Surface treatment is very diverse for metal injection molding(http://www.zcmim.com/manufactureequipment.shtml) product. Let’s discuss electrochemical method firstly. This method is by using electrode reaction, to form coating on the surface of product. Its main method is:

(1) electroplating

In electrolyte solution, product is anodal. Under external current, product surface form a coating. The coating can be metal, alloy, semiconductor or all kinds of solid particles, such as copper, nickel, etc..

(2) oxidation

In electrolyte solution, product is anodal. Under external current, product surface form an oxide film, which is called anodic oxidation, such as aluminum anodic oxidation.

Original article link：http://www.zcmim.com/article/metal-injection-molding-stt_1.html

Powder Metallurgy Process—Pouring Gate in Mould

powder metallurgy process

Definition of pouring gate in mould for powder metallurgy process （http://www.zcmim.com/）:  pouring gate is also called  feeding throat or inner sprue. It is a narrow part between the runner and product, also known as the shortest part in gating system.ong
Pouring gate role in powder metallurgy process: can  speed up the rapid of melting material transporting from runner to be a ideal and order flow and filled with cavity quickly; at the same time, pouring gate  also  play the role of closing  cavity to prevent from reverse liquid;  make separating  products from gating easier after molding.

Original article link：http://www.zcmim.com/article/powder-metallurgy-process-pmp_1.html

Metal Injection Molding—Mould Sub-runner

Sub-runner in metal injection molding mould refers to a mainstream between sprue and gate. It is the transition for melting material flowing from sprue into cavity and  through section area change to material diversion in pouring system. It can make material get a smooth transformation.
 Section Design 
A. General design  is circular
B. Considering better process, it is usually designed to U shape, V shape, trapezoidal shape or hexagon shape
C. Shape and size of section should be based on the volume,  wall thickness, shape of products as well as  process properties, injection speed and length of runner.
 
2. There are two layouts for runner:  balanced  feed and non-balanced  feed. Balanced feed is to ensure each feeding throat  fed  evenly at the same time. The unbalanced feed refers to not  feeding  each feeding throat  evenly at the same time. Generally it is evaluated through mold flow analysis.

Original article link：Metal Injection Molding http://www.zcmim.com/article/metal-injection-molding-mimms_1.html

What are the Characteristics of Powder Metallurgy Technology?

Powderinjection molding technology can maximum reduce the segregation of alloy composition, and eliminate bulky and inhomogeneous casting organization, can use high performance non equilibrium materials such as non crystal, ceramics, nano crystalline and super saturated solid materials. These materials have excellent optical and mechanical properties.

Powder injection molding technology can easily achieve a variety of types of compound, fully play the each kind raw material’s characteristics. So it is a low cost process for producing high performance metal and ceramic products.

 MIM powder injection molding technology can realize automatic lot production, so as to reduce resources and energy consumption. Hence powder metallurgy technology is a kind of new technology which can be used effectively for regeneration and comprehensive utilization.

Original article link：http://www.zcmim.com/article/metal-injection-molding-mimms_1.html

Metal Injection Molding Blade

Metal Injection Molding Blade is made from mould, so the outline of the blade, the consistency of the shape and size are very good. By sintering,sizing , heat treatment, surface hardness can achieve HRC = 50 or so. Thereby it just need open blade in mechanical cutting. Material properties make it able to be done post treatment such as ectroplating and coating to improve the wear resistance and surface finish.

Original article link：http://www.zcmim.com/article/metal-injection-molding-mimb_1.html

Metal Injection Molding Process SIM Card Slot

Metal injection molding process SIM card slot have two kinds: single card slot and double card slot. Some card slot covers are made from Aluminum by lathe. Hold card position can be coated in case of electric conduction. Because of thin and complicated shape, compared with other process, MIM has obvious superiority, high efficiency and low cost advantage.

Original article link：http://www.zcmim.com/article/metal-injection-molding-process-scs_1.html

How to control the cost during the process of MIM?

The first step is to purchasing cost. The purity of powder metallurgy products between 95%-98% in general, and the procurement cost of raw materials is equal to the cost of each gram of metal materials costs x parts cubage x parts density. So to control the cost, the volume of the part is to be the precise calculation.

The second step is how to produce. The pressure is not the same different requirements of the product to, so the cost will be different. MIM ( powder injection molding http://www.zcmim.com/ ) products used in the suppression of the equipment isn’t more, and the speed should be fast.

Finally is control the mold cost, we need to choose the high pressure materials when we choose the material as a mold material, which can ensure product specifications more accurate.

Original article link：http://www.zcmim.com/article/metal-injection-molding-httcdt_1.html

Surface treatment of MIM- steam treatmen

Surface treatment of MIM (powder injection molding) steam treatment is through the pressure of steam and in the range temperature (such as 550-570 degree ) for a period of time, make the oxide films on the iron-based surface , which prevent iron further corrosion; General process of steam treatment is the removal of oil ,then water washing, then pickling, then water washing (surface is dealt with in the smooth state)  then loaded furnace steam treatment (1-2) and oil immersion treatment; steam treatment need to spent a long time and large energy consumption, temperature and pressure change can produce iron oxide, Fe2O3, or the Fe3O4 ;  if it has dark red on the surface after steam treatment which means the parts have been corroded.

For the expansion of steam treatment, which can increase of the powder metallurgy parts hardness and brittleness; Through the adjusting the temperature or pressure not sure to solve the problem; Fe3O4 can seal the micro-hole and maybe change the local structural through expansion; steam treatment’s loading, due to product overlap, some products can appear grow dim in visible or invisible.

Original article link：

http://www.zcmim.com/article/mim-powder-injection-molding-stom_1.html

Mould Main Channel introduction in Metal Injection Molding Process

Definition: main channel refers to the part  from  interface between injection machine nozzle and mould, to the end of sub-runner.

2. Mould design notice before metal injectionmolding process

(1)   Head face for main channel is usually round shape.

(2)   In general, the main Channel will design some inclination for ease to release from mold . But when the main channel across a number of boards at the same time, it is important to note that each pieces inclination size and hole size.

(3)    main channel size is subject to the flexibility of materials

(4) the main channel mostly use conical. Note follows  when you make mould:
A. the small end diameter D2 = D1, D2 + (0.5 ~ 1 mm)
B. the small end radius R2 = R1 + R2 (1 ~ 2 mm)
(D1, R1 refer to the diameter and radius of injection machine nozzle )

Original article link：http://www.zcmim.com/article/metal-injection-molding-process-mmcimi_1.html

Sprue Bushing Introduction for Metal Injection Molding Mould

Definition: as for the contact and collision between main channel, high temperature material and nozzle, main channel is usually designed  to be replaceable bushing, hereinafter referred to sprue bushing.

(1)  Main role:
A. Make mould install into hole easier and better fit injection machine nozzle hole.  and can withstand the back pressure of material in case of push off from mould.

B. As main channel of the gating system, sprue bushing  transits material from cylinder into mould cavity smoothly. During metal injection molding process, material is unallowed  overflow.  At the same time sprue bushing ensures main channel setting out  conveniently.

( 2)  Structure
Integral type: shoulder and main channel parts are integrated
Split type: shoulder and main channel parts are made separately
Japanese  industrial standard: JIS
Chinese  industry standard: SJB

Original article link：http://www.zcmim.com/article/metal-injection-molding-proces-mimci_1.html

Domestic Development of Powder Injection Molding Technology

So far, hundreds of companies across the world have engaged in metal injection molding product development, research and sales. Metal injection molding process thus has become the most active cutting-edge technology in new type of manufacturing industries. MIM represents the main direction for powder metallurgy. 

The development of metal injection molding technology in China can be said that it benefits from the mobile phone industry. Since year 2009, the whole industry skyrockets; especially after middle 2011. Because of competition between Apple and Samsung, MIM parts are widely used in handheld device sets. I had never seen it before.

Metal injection molding process combined with the advantages of powder metallurgy and plastic injection molding, and opened up a new research area.

Original article link：PowderInjection Molding Technology

Can You Imagine that the DIY Creative Earrings are Made of Small Gears?

In creative person’s eyes,  anything can be formed eye-opener objects. For example, can you imagine that MIM metal injectionmolding small gears can be made creative DIY earrings?

Today I saw a very interesting DIY creative image occasionally. Looking at the picture, it is a creative earring composed of a watch movement and small gear, a very beautiful and interesting DIY creative earring. Like industrial parts, ordinary people can only try to use for hardware machinery, but for these creative people, you will find another shining point.

Original article link：

http://www.zcmim.com/article/mimmetalinjectionmoldingdiycea_1.html

Metal Injection Molding

Metal Injection Molding Process (http://www.zcmim.com/), first of all, mixing solid powder and organic binder evenly. After that, inject into mould cavity by injection machine in heating condition , then use chemical or thermal decomposition method to remove binder from blank. After the final results of sintering, get final product with good strength, hardness, high mechanical properties such as elongation, good brightness, good abrasion resistance.

Original article link：http://www.zcmim.com/article/metalinjectionmoldingprocessi_1.html

MIM Metal Injection Molding Parts

Sophisticated geometry products can also be made by Metal Injection Molding MIM even have difficulty for molding. It can once molding similar to production of plastic products. Metal Injection Molding parts（http://www.zcmim.com/bymaterial.shtml） have with wide choices of raw materials and high utilization efficient. Product quality is stable and have reliable performance. MIM can be widely used in all areas and realize mass production at low cost.

Original article link：http://www.zcmim.com/article/metalinjectionmoldingpartsl_1.html

MIM Metal Injection Molding Product Process Changes

Cellphone Camera Metal Circle

The equipment and technology of metal injection molding are similar to that of plastic injection molding. The granular material is fed into the machine for heating then injected into mold cavity under high pressure. Product in this process called green part.

the entire process to mold can be designed as a multi cavity to increase productivity.

The die cavity is designed to be more than 20% of the metal part to compensate for the shrinkage during sintering. The shrinkage variation of each material is accurate and known.

Original article link：MetalInjection Molding

Debinding in Powder injection molding

MIM powder injection molding(link: http://www.zcmim.com/bymaterial.shtml) of stainless steel part mainly use wax-based thermoplastic binder. Stainless steel debinding technology is divided into heat debinding, solvent debinding, skim debinding and catalysis debinding, among which the most widely used is solvent bebinding. Solvent bebinding removes most binder through dissolution and other methods, only leaving connected channel. These connected channels can make low relative molecular gas quickly spread to the outside of blank that produced in the process of subsequent heat debinding, so that the subsequent heat debinding process can be carried out quickly. The purpose of debinding is to remove the binder rapidly without defects such as porosity.

Product will become very fragile after removing binders. But we must ensure the spare parts’ shape. Current technology is usually combine debinding and sintering process. The binder can be completely removed before heating temperature reached sintered standard.

Original article link：http://www.zcmim.com/article/mimpowderinjectionmoldingdipim_1.html

Mould’s Basic Structure in Metal Injection Molding

MetalInjection Molding(MIM) structure can be divided into: molding system, gating system, exhaust system, cooling system, ejection system etc

What is gating system? It refers to the flow channel from injection machine nozzle to  cavity. It is formed by main runner,   distributary channel, gate and cold slug well. Related words are:

CAV.NO., RUNNER,GATE , CAVITY  

Original article link：http://www.zcmim.com/article/metalinjectionmoldingmbsimim_1.html

Cloudy in Metal Injection Molding Process

Deformation phenomenon explains in Metal Injection Molding as:  product surface covered with a layer of milky film, like insufficient glossiness because of mist covering.

The causes and treatment:
- rough mould, lack of brightness
- mould and material’s temperature is too low
-improper use of mold release agent
- disintigrating plastic additives or gasification in mold surface

Original article link：http://www.zcmim.com/article/metalinjectionmoldingascmimp_1.html

Headlamp Lens table lamp crafted of industrial parts and vintage auto headlamp lens

Headlamp Lens table lamp crafted of industrial parts and vintage auto headlamp lens - sold in San Diego,

Detection method of grain size distribution for MIM powder in powder injection molding

 The grain size distribution is usually measured by laser granularity analyzer in MIM powder injection molding. Because laser has a good mono chromaticity and extremely strong direction. When light encounters a particle, a portion of the light scatter. 

   The direction of scattered light and the direction of central beam form an angle, whose degree is related to the size of the particle. The larger grain size, the smaller angle for light scattering . The smaller the particle size, the larger angle. Scattering light intensity represents particle quantity. Hence scattered light intensity measured in different angle can get particle size distribution of sample.

Original article link：

http://www.zcmim.com/article/mimpowderinjectionmoldingdpgadfm_1.html

The most attractive technical characteristics of MIM metal powder injection molding

MIMmetal injection molding has combined two advantages of powder metallurgy and plastic injection molding technology, broken through shape limit of traditional metal powder die pressing process. At the same time, Taking advantage of plastic injection moulding technology, MIM can efficiently mass produce complex shape parts, such as a variety of external cutting groove, external thread, tapered outer surface, cross through holes, blind holes, concave station, key pins, strengthen rib plate, surface knurling and so on.

Advantages of MIM technology:

A. direct forming sophisticated parts, usual weight of 0.1~200g

B. fine surface finish and high precision, typical tolerance is + 0.05mm

C. good flexibility and wide application of alloys. The products has density of 95%~99%; internal structure is uniform, no internal stress and segregation.

D. High automatic production, no pollution, can realize continuous clean mass production.

Original article link：http://www.zcmim.com/article/mimmetalinjectionmoldingtatcompio_1.html

MIM Metal Injection Molding

Metal Injection Molding (MetalPowder Injection Molding MIM) is a new high-tech process combining traditional powder metallurgy technology with plastic Injection Molding technology.

Firstly choosing satisfactory MIM powder and  binder, then under a certain temperature mixing them to make into feedstock by  appropriate method. After granulating, the feedstock can be used directly for injection, debinding and sintering, and finally gain the final product.

Original article link:

http://www.zcmim.com/article/metalpowderinjectionmoldingmimmmim_1.html

MIM Metal Powder Injection Molding

Metal Injection molding, called MIM,  can produce fine quality mechanical parts with good density and perfect mechanical properties refers to metal powder characteristics.

At the same time, it can efficiently mass produce sophisticated parts, such as various external grooving, cross hole, blind hole, concave and pins, rib plates, knurled surface and so on, which are all unable to be made by conventional powder metallurgy method and precision casting process. MIM material is widely including: refractory, difficult casting and difficult processing materials.

Original article link:

http://www.zcmim.com/article/metalinjectionmoldingmmpim_1.html

Delamination and Cloudy in Metal Powder Injection molding

Delamination in metal powder injection molding, process  is: finish product present micaceous structure. It can be easily split between layers
Analysis causes and find treatment for it:
- mix in dissimilar material
- temperature of material is too low

Cloudy phenomenon in metal powder injection molding  process is: a layer of milky film coved product surface, just  like covered by mist, which make insufficient glossiness. causes and treatment:
-  rough mould and insufficient  brightness
- mould and material’s  temperature are too low

-improper use of mold release agent
- addition agent pyrolyse or gasify on mould surface

Original article link：http://www.zcmim.com/article/metalpowderinjectionmoldingprocess_1.html

Deformation in Powder Injection Molding

Deformation phenomenon explains in powderinjection molding as: poor cooling contraction, bad molding conditions and releasing make molded products , remain stress inside, which lead to deformation is divided into warping, distortion.

Causes and treatment:
- injection pressure is too high or too short holding time

- insufficient cooling time

- rough mould or draft angle is insufficient
- bad design for rib thickness and height
- mould plate’s temperature is great different or inhomogenous cooling
- too low temperature of material, flow direction and vertical direction shrinkage difference greatly.

Original article link：http://www.zcmim.com/article/powderinjectionmoldingdpim_1.html