Abstract
The ceramic injection molding (CIM) process is a cost-effective powder-based near net shape manufacturing process for large-scale production of complex-shaped ceramic functional components. This paper presents the rheological analysis of environmentally friendly CIM feedstock formulations based on the binder components polyvinyl butyral (PVB) and polyethylene gycol (PEG). The prepared PVB/PEG-based alumina molding compounds were investigated with respect to their PVB:PEG ratios as well as to their powder filling degrees in the range between 50 and 64 vol.%. Corresponding viscosities and shear stresses were determined for increasing shear rates to show the effects of increased PEG content and solid loadings on them. Two single reactor components were injection molded and subsequently joined in their green state for fabrication of an alumina microreactor. The intended purpose of the alumina microreactors is their potential application as wear-resistant and hydrothermal stable multifunctional devices (µ-mixer, µ-reactor, µ-analyzer) for continuous hydrothermal synthesis (CHTS) of metal oxide nanoparticles in supercritical water (sc-H2O) as the reaction medium.
Highlights
Powder injection molding (PIM) technology is a popular batch fabrication process for pure polymers or polymeric feedstocks with ceramic or metal particle load [1]
For feedstocks referring to the binder system of formula F1, the maximum powder load lies below 60 vol.%, even though polyvinyl butyral (PVB)/polyethylene gycol (PEG)-based molding compounds with higher filler degrees can be prepared and they are partially readily processable via ceramic injection molding (CIM) if, for example, low shear rates are applied
The rheological and thermal properties of CIM alumina feedstocks based on different ratios of the organic additives PVB and PEG were investigated to gain knowledge about their effect on the feedstocks’ viscosities and their pseudo-plasticity of highly filled molding compounds
Summary
Powder injection molding (PIM) technology is a popular batch fabrication process for pure polymers or polymeric feedstocks with ceramic or metal particle load [1]. It enables cost-effective mass production of microstructured and complex-shaped components for high performance applications [2]. Using additive manufacturing technologies like PolyJet 3D printing technology for rapid tooling of polymer injection mold inserts, the PIM process becomes attractive for design studies and rapid prototyping. Ceramic injection molding (CIM) processes are generally divided into four steps: (1) compounding;. Defects in the final parts created during injection molding cannot be eliminated during step three and four [5]. High-pressure is applied during PIM processes and the binder system serves a very important role [7]
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