Abstract
From the micro-powder injection molding (μPIM) process, a two-component micro-powder injection molding (2C-μPIM) process has evolved due to the growing demand for multi-functional micro-components in avant-garde applications. 2C-μPIM technology provides the opportunity to conjugate distinct materials within one part. Stainless steel (SS 17-4PH) and 3 mol.% yttria-stabilized zirconia (3YSZ) are characteristically recognized for their corrosion resistance and high hardness. In this work, the obtained critical powder volume concentration (CPVC) of SS 17-4PH and 3YSZ powders were 71.7 and 47.1 vol.%, respectively. Solid loadings of 2 and 3 vol.% less than the CPVC were considered as the optimal content for both powders. Feedstocks were obtained by mixing SS 17-4PH and 3YSZ powders with a binder system comprised of palm stearin (PS) and low-density polyethylene (LDPE). The rheological behaviors of the prepared feedstocks were assessed to figure out the feedstocks having the best rheological properties. The feedstocks of SS 17-4PH and 3YSZ with powder loadings of 69 and 44 vol.% were eventually injected to produce bi-material micro-parts. The optimal solvent debinding temperature of the green bi-material micro-part was then investigated, and it was found that 73.3% soluble binder was removed when bi-material was immersed in acetone at 70 °C for 40 min.
Highlights
The global trend towards the miniaturization of products and the necessity of incorporating different functional capabilities within one micro-component have played a significant role towards the evolvement of the two-component micro-powder injection molding (2C-μPIM) process from previous micro-powder injection molding
The optimal powder loading system was selected for this experiment
The feasibility of using SS 17-4PH and submicronic 3 mol.% yttria-stabilized zirconia (3YSZ) powder to prepare bi-material green micro-parts and their solvent debinding behavior were investigated in this study
Summary
The global trend towards the miniaturization of products and the necessity of incorporating different functional capabilities within one micro-component have played a significant role towards the evolvement of the two-component micro-powder injection molding (2C-μPIM) process from previous micro-powder injection molding (μPIM). The significant use of material and low production costs has contributed towards 2C-μPIM as a commendable manufacturing technique in which two dissimilar materials can be joined, thereby producing a smooth gradient interface using a similar injection molding machine [1,2]. The joining of metal and ceramic is considered to be an excellent option for applications in several engineering fields and industries. This is because ceramics display high resistance to corrosion and wear but they exhibit persistent mechanical and thermal properties at elevated temperatures, whereas metals are ductile with excellent thermal and electrical conductivity. The implementation of the 2C-μPIM process is first initiated with the mixing of Metals 2020, 10, 595; doi:10.3390/met10050595 www.mdpi.com/journal/metals
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