Abstract
It is known that Fe-9.6%Si-5.4%Al alloy called “Sendust” is soft magentic material well suited for a magetic head becuase of high permeability and high magnetic flux density and high resistance to wear as well.A series of investigations have been made by the authors to improve mechanical properties of this alloy, for instance, by extrusion of powder for higher density and finer grains. The metal injection molding process widely adopted in recent years was tried in this work first to manufacture near-net shape products of such very brittle material as this composition from gas-atomized powder and then to improve density and grain size.A comparison was also made between the injection molded and the cast material of the same composition.We have found some characteristics mentioned below of the Sendust alloy injection molded from gas-atomized powder.1) -38μm powder, coarser than -20μm regularly used for metal injection process, was molded successfully from compound of 69vol.% powder which was higher than a usual ratio.2) Such coarse powder as -38μm was processed to satisfactorily dense, evenly fine grained and segregation-free material of good magnetic properties with stability in shape.
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