Effect of nano-sized powders on powder injection molding: a review

Abstract

This review presents a thorough survey of academic work on the analysis and application of the usage of nano-sized powders in powder injection molding (PIM). The PIM process has become well-established in the fabrication of micro parts or microstructured parts in recent years. Given their unique inherent properties, nano-sized powders are widely used over micro-sized powders in all high-volume PIM methods of fabricating metal and ceramic components. Current critical issues are discussed, such as the effect of nano-sized powders on the mixing, injection, debinding, and sintering processes, as well as the effects on the feedstock and final properties of the components. Based on this survey, the current study proposes improvement on the limitations caused by applying nano-sized powders in the PIM process by utilizing new binder systems, milling, new deagglomeration methods, and new sintering procedures. Fields and topics that require further research are identified, and prospects for future industrial implementation of the process are given. This study is the first to aims at providing insights into the effects of using nano-sized powders in the PIM process. Moreover, this paper shows the great potential for further investigations and innovation in the field of powder injection molding using nano-sized powders.