Abstract
The processing of advanced materials such as refractory ceramics and metallic alloy powders has been investigated intensely over the past two decades. Ceramic injection moulding has therefore become a prime method for manufacturing complicated parts from a robust material. Typically, powder is dispersed within a thermoplastic carrier (or binder) before it is moulded at high temperatures and pressures. Further removal of the binder by thermal or solvent degradation methods yields a component that is suitable for sintering. Within industry, components have been manufactured with densities greater than 95% of theoretical. However, this processing route has its drawbacks. De-binding can take days due to slow heating rates and changes in viscosity of the polymeric carrier that can delay production and increase costs. A solution has been found by using a reactive binder that can polymerise within seconds and degrade back to a monomer within a fraction of conventional de-binding times. This technology, known as powder reaction injection moulding engineering (PRIME), has been developed using a cyanoacrylate binder that is commonly used as an adhesive, thus introducing difficulties when moulding. This paper describes the processing limitations of this binder and the method for moulding a conduit ceramic part.
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