Assessing PM's ‘green’

Abstract

The influence of powder characteristics on the moldability of metal injection molding feedstock is relatively well understood, but remains difficult to quantify other than by real-scale injections. This study aims to correlate feedstock moldability performances with melt viscosity and dry powder rheology. Four stainless steel powders exhibiting different particle sizes and shapes were tested in dry conditions using an FT4 powder rheometer to obtain thirteen different powder rheology-related metrics. These powders were subsequently mixed with a wax-based binder to formulate four feedstocks that were tested in melt conditions using a rotational rheometer to characterize the injection-related rheology of the feedstock formulations. The moldability of the feedstocks was finally quantified using real-scale injections performed into a spiral mold cavity to measure the injected lengths, and the correlation between the dry and melt rheology metrics and the real-scale injection moldability was evaluated. Results showed that the feedstock melt viscosities and the injected lengths were almost perfectly correlated. Furthermore, two dry powder rheology metrics, namely, the normalized basic flow energy and the conditioned powder bulk density, showed the correlation with the feedstock moldability which is comparable to that obtained with the melt rheology. The results of this study indicate that although the feedstock melt viscosity and the dry powder rheology take fewer variables into account as compared to real-scale injections, these simplified tests (especially dry powder rheology) could be considered as rapid and reliable approaches to assessing the impact of powder characteristics on the moldability of powder-binder feedstocks used in metal injection molding.