Beruflich Dokumente
Kultur Dokumente
DESIGN GUIDE
PHILLIPS PLASTICS CORPORATION
1. Feedstock Mixing
Attention to detail at the mixing step is critical to ensure the homogeneity of the feedstock over the long run. MIM feedstock begins with extensive characterization of very fine (less than 22 micron) metal powders. These powders are carefully hot mixed together with polymeric binders to form a uniform mixture. This mixture is then cooled and granulated to form the feedstock for the injection molding machine.
2. Molding
Phillips specially equipped injection molding machines are designed to mold a metal/polymer feedstock. Combining over 42 years of injection molding experience with advanced processing instrumentation and software ensures tight control of this process producing consistent components with unvarying density. If in-cavity pressure transducers indicate the molding cycle is out of predetermined limits, the closed loop feedback system rejects parts automatically. Most of the advantages of using Phillips MIM capabilities are realized in the molding step, where complex contours, holes, small radii, logos, and text can be molded in. The molding process creates virtually no waste since runners can be reground and molded again without compromising the properties of the final part. In the molding area, extensive automation is also employed to palletize parts directly onto ceramic setters. This automation eliminates the unnecessary handling of parts, providing consistent and cost-effective manufacturing solutions.
3. Catalytic Debinding
The advanced debinding technology used by Phillips is the most efficient form of debinding. Harnessing the power of polymer chemistry, Phillips introduces a catalyst to remove 90% of the binder from the green part. Because catalytic debinding occurs at temperatures below the softening point of the binder, parts are processed with excellent shape and dimensional integrity. After the binder has been removed, the result is termed a brown part. The brown part consists of a porous matrix of metal powder and a small amount of binder, sufficient to allow the part to retain its shape.
4. Sintering
In the final step, the brown parts are sintered using a temperature and atmosphere profile chosen specifically for the alloy being processed. At the lower temperatures of the sintering cycle, the residual polymer binder is removed. As the temperature increases, sintering begins. Neighboring particles fuse and bond to one another bringing the structure together and reducing porosity. Ultimately, the required physical properties are obtained and densities between 96-99% of theoretical are achieved. During the densification process, depending on the material being processed, liner shrinkage of 14-22% occurs. This shrinkage is predictable and compensated for by over-sizing the mold cavity. Typical as-sintered tolerances are within 0.30 to 0.50 (0.003 to 0.005 inches-per-inch).
components for the MIM process, part count and assembly time are reduced resulting in overall cost savings.
2
1 Green or as molded parts 2 Brown parts. Same size, but 90% of the binder is gone 3 Sintered parts. 96+% dense. Size meets print
Molding
Debinding
Heater Bands
Mold
Exhaus
Heater Coils
Feedstock
Feedstock Preparation
Powder and polymer binder are hot mixed to produce a homogenous mixture
Catalytic Debinding
Sintering
st Burner Brown Parts Fan Catalyst Shrinking Core Mechanism Secondary Binder Continuous Furnace
8-10 Preheat and Hot Zones
Sintered Parts
Debind Characteristics
Process Parameters Chemical reaction Shrinking core mechanism Temperature is below softening point of binder Process Keys Fast (2-4 hours) Clean No distortion of parts
Sintering Characteristics
Linear shrinkage of 14-22% Sintered density of 96-99% of theoretical Mechanical and corrosion properties comparable to wrought
Tooling Expertise
MIM molds are similar to those used for plastic injection molding. As in tooling for plastic injection molding, molds are often designed with multiple cavities to reduce processing costs. Phillips in-house tooling capabilities can be employed to ensure a seamless line of communication during the tooling phase of the program. Although lead times vary from one program to another, typical MIM tooling lead times are 4-8 weeks. A Phillips representative can assist in determining the cost-effectiveness for individual programs.
Flexible Capabilities
Phillips metal injection molding facility is equipped with both batch and continuous debinding ovens and sintering furnaces. Continuous debinding and sintering provides the temperature uniformity and consistent processing conditions for a wide range of materials. The result is excellent dimensional repeatability at the lowest possible cost for programs with extremely high throughput requirements. Batch sintering compliments Phillips continuous furnace capability by providing the flexibility to run smaller batch sizes in product development cycles. Batch sintering also allows Phillips to run larger parts, in the 120 grams range or higher, that would not be well suited for the continuous furnace process. In addition, with the vacuum capabilities of these furnaces, specialty materials like titanium can be processed.
Phillips batch debind ovens and furnaces are equipped to handle a wide variety of MIM materials
Automation
Extensive automation is employed to maintain constant cycle times and minimize part handling. Consistency and a lower overall cost to customers are the results.
In A Flash
Phillips reputation for producing high quality parts in an accelerated time frame begins at the design phase of a program. At one of two in-house design development centers, Phillips team can create high quality MIM parts in as little as two weeks.
One of the more traditional metalforming processes, MIM competes on a material and geometry basis directly with investment casting and machining. In other words, similar geometries can be produced in a given material by each of these three processes. MIM excels when part complexity is high, overall component size is small, and production volumes are 10,000 or more. MIM competes against die-casting on a geometry-only basis. Here, the same geometries can be produced by both processes, but material choices are different. Compared with aluminum, zinc, or magnesium die castings, MIM components offer far superior strength, hardness, and corrosion resistance properties. In most cases, the higher properties of MIM come at a slightly higher cost when compared to die-cast components. MIM may compete economically with stamping or the conventional powder metal process when two or more of these components are combined into a single MIM design. By reducing part-count and eliminating assembly hassles, a lower overall cost can be achieved. The greater design flexibility of MIM allows features like blind holes, threads, and wall thickness changes to be molded-in from the start rather than added later as secondary operations.
Phillips continuous debinding and sintering furnace provides quality processing and large volume capacity while maintaining consistent quality
Investment Casting
MIM can produce thinner wall sections and sharper cutting points Better surface finish Better for small diameter blind and through holes Finish machining required is greatly reduced High volumes of small components are produced at lower cost and faster lead times
Die-Casting
MIM alloy selections offer superior corrosion protection Superior wear resistance Superior strength and hardness Larger material selection
MIM can mold geometries that eliminate secondary operations Superior density and corrosion performance Superior strength and ductility Combining two P/M parts can reduce part count Superior magnetic properties
Design Considerations
When designing MIM components, the engineer can begin with a clean slate, adding material in uniform wall sections only when needed. This thought process is much different than designing for machining, where reducing the amount of metal removed from a square or round stock can be an important consideration. Because MIM allows the designer to reduce material content to only what is functionally required, MIM parts are generally smaller and lighter than their machined counterparts. The MIM designer is also freed from the restrictions imposed by the capability of the machining equipment. The design freedom with MIM is largely the same as with plastic injection molding. Whether the designer makes improvements by reducing material content, combining multiple components, or by molding in text and logos, the earlier Phillips MIM engineers are involved, the greater the chance to experience the full benefits of metal injection molding.
by MIM are similar to those made by conventional plastic injection molding or die-casting.
Draft
On complex shapes where draft is required, the normal range is 0.25 to 0.50 degrees. In many cases, parts can be produced with no draft.
Wall Thickness
To avoid internal stresses, voids, and sink marks, walls of uniform thickness are ideal. Thicknesses in the range of 0.050 to 0.250 inches are preferred, but exceptions in both directions are routinely done. Parts have been produced with wall sections as little as 0.005 inch and as large as 0.50 inch. Consult a Phillips metal injection molding engineer for details.
Ribs and webs are useful for reinforcing relatively thin walls and avoiding thick sections. They improve material flow and limit distortion, while increasing strength and rigidity of a thin wall. Rib thickness should not exceed that of the adjoining wall.
Fillets and radii eliminate sharp corners, which reduces stress at the intersection of features and facilitates the flow of feedstock into the mold cavity.
Undercuts
External undercuts can be formed anywhere in the part. Internal undercuts can be formed using collapsible cores, but they are generally not considered economically practical. Phillips has the capability to machine internal undercuts as a secondary operation, when required.
Threads
External and internal threads can be molded using MIM technology; however, secondary tapping is usually more precise for internal threads. External threads are normally produced with a small flat area on the parting line of the mold to eliminate potential interference from the parting line.
Design Considerations
When designing for the MIM process, engineers should be aware of the following requirements of the molding process:
Parting Line The parting line is the plane in which the two mold halves meet. To the extent possible, all features should be oriented perpendicular to the plane of the parting line to facilitate removing the part from the mold. Slides and lifters can be incorporated for components that cannot be perpendicular to the parting line Gate Location The optimum location of gates is a balance between product and processing requirements. In general gates should be positioned to direct the flow onto a core pin or cavity wall. Where wall thickness varies, gates should be located so the material flows from the thicker to the thinner sections.
Witnesses Because a MIM component begins as an injection molded part, witnesses such as parting lines, ejector pins, and gates will be present. When designing critical features into a part, consideration of the location of witnesses should be addressed with Phillips team of experts. Provisions for Sintering Metal injection molded parts are typically placed on flat, ceramic fixtures for sintering. Parts with long cantilevers and spans are not self-supporting and generally require ribs, added supports, or custom fixtures for sintering. Whenever possible, the part designs should include a flat surface to eliminate the need for these custom fixtures. For more complex shapes, custom setters can be utilized for highly detailed geometries.
Secondary Operations
Phillips can provide secondary operations to meet an array of specific requirements. Since typical tolerances for the MIM process are within 0.003 to 0.005 inches per inch, (0.3-0.5%), many parts are sintered to final dimensions. If tighter tolerances are required in certain areas, secondary-machining operations can be applied. Tapping operations can produce internal threads with tolerances tighter than can be achieved via the metal injection molding process. Tumbling and polishing can provide an aesthetic surface. Parts can be heat-treated; black oxide coated, and plated in similar fashion to investment cast or machined parts.
- Milling - Turning - Grinding - Tapping - Lapping Surface finishing - Passivation - Black oxide - Nickel - Gold - Chrome - Bead blasting - Tumbling - Electro-polishing - Titanium nitride Calibration - Coining - Sizing - Straightening Heat Treatment - Through hardening - Case hardening - Annealing - Ageing - Tempering
Materials
Phillips Metal Injection Molding offers several alloys that are used in a wide variety of automotive, electronic, medical, magnetic, and consumer applications. Injection molded alloys include: Stainless steels Titanium Tool Steels Low alloy steels Soft-magnetic alloys Controlled expansion alloys High temperature alloys
UTS (MPa)
650 1450 650
Elongation (%)
Density (g/cm3)
7.4 7.4 7.4 7.4
Hardness (HRC)
130-230 HV10 45 HRC 190-230 HV10 650 HV1 150 HV1 55 HRC 90-110 HV10 55 HRC 90-140 HV10 600 HV10
3 2 3
42CrMo4(4140)
heat treated
5 2 25
Fe-2% Ni
as-sintered
210
380
15
7.5 7.5
Stainless Steels
316L 310
N2 sintered
50% 16 35 5 2
120 HV10 235 HV1 270-300 HV10 38 HRC 48 HRC 45 HRC 55 HRC
440 B 440 B
Refers to typical properties for through-hardened Fe-2% Ni and Fe-8% Ni. These alloys can be heat-treated to achieve a range of case or through hardness depending on the application. The corresponding strengths and ductilities vary depending on the heat-treated condition. 1 Mpa = 145 psi Note: All properties are typical. Phillips Metal Injection Molding does not warranty that these materials are fit for any particular purpose. All materials need to be tested by the customer to assure they meet minimum performance criteria.
UTS (MPa)
1200
Elongation (%)
Density (g/cm3)
7.9 7.9
Hardness (HRC)
50 HRC 64 HRC
1.0
Special Alloys
HX (Hastelloy X) Titanium
(CP Grade 4) sintered and solution annealed)
35 5 24
Kovar (F15)
non-magnetic
Tungsten (W)
1 Mpa = 145 psi Note: All properties are typical. Phillips Metal Injection Molding does not warranty that these materials are fit for any particular purpose. All materials need to be tested by the customer to assure they meet minimum performance criteria. Kovar is a registered trademark of Carpenter Technology Corporation
Fe
Ni
Cr
Si
Mo
Cu
Mn
Others
Bal. Bal. Bal. Bal. Bal. Bal. 0.4-0.7 1.50-2.50 1.90-2.20 7.50-8.50 7.50-8.50
0.9-1.2 0.4-0.6
Stainless Steels
316L 310 PANACEA 17-4PH 420 440 B Bal. Bal. Bal. Bal. Bal. Bal. 10-14 19.0-22.0 0.10 3-5 16-18 24.0-26.0 16.5-17.5 15-17.5 12-14 16-18 0.03 max 0.2-0.5 0.20 0.07 max 0.18-0.30 0.75-0.95 1.0 max 0.75-1.75 1.0 1.0 max 1.0 1.0 0.75 3.0-3.5 3.0-5.0 2.0-3.0 2.0 max 1.5 10-12 1.0 max 1.0 1.0 1.2-1.5 Nb 0.75-0.90 N 0.15-0.45 (Nb + Ta)
Tool Steel
M2 Bal. 3.80-4.50 0.95-1.05 4.5-5.5 W 5.50-6.75 V 1.75-2.20
Special Alloys
HX (Hastelloy X) Titanium (CP Grade 4) Kovar (F15)
Tungsten (W)
17-20 Bal.
Bal. 28.5-29.5
20.5-23.0
0.05-0.15 0.20
1.0
8-10
1.0
0.5-2.10 Co, 0.20-1.0 W, 0.008 B Ti Bal. (O 0.40, N 0.10) Co 16.5-17.5 94% W Bal. (Ni, Cu, Co)
Coercive Force
Hc (Oe)
0.125 0.36 0.918 0.92
Maximum Permeability
max (B/H)
27,270 14,236 5,215 3,311
1 Oerstad (Oe) = 79.55 ampere/meter (A/m) 1 kiloguass (kG) = 0.10 tesla (T) Note: All properties are typical. Phillips Metal Injection Molding does not warranty that these materials are fit for any particular purpose. All materials need to be tested by the customer to assure they meet minimum performance criteria.
Cr
Fe
Co
Al
Ti
Mn
Si
Ni
0.13
18-21
1.5
15-21
1.0-2.0
3.0-4.0
1.0
1.0
Bal.
Yield Strength
sintered + heat-treated HIP + heat-treated
UTS
1220 MPA 1270
Elongation
14 33
Density
8.0 8.18
Hardness
350 HV10 385 HV10
Material
CHS-4
after sintering at 20C
Si
Mn
Cr
Ni
Mo
Fe
2.2
1.6
1.0
12.0
39.0
6.0
0.9
0.5
Bal.
Yield Strength
600 MPA
UTS
800 MPA
Elongation
2.0
Density
7.9
Hardness
33-37 HRC