“Results on Powder Injection Molding of Ni3AI and Application to Other Intermetallic Compositions”

Abstract

Net shape forming processes are under development to allow affordable production of intermetallic components. Powder injection molding (PIM) may be employed for the production of complex-shaped intermetallic geometries. Proper choice of powder parameters and processing conditions can lead to the formation of fully dense structures through pressure-less sintering. In this study, Ni 3 Al with 0.04 wt.-% boron has been successfully injection molded and sintered to full density. A yield strength of 340 MPa, ultimate tensile strength (UTS) of 591 MPa, and 8 % elongation were attained for injection molded and sintered tensile bars. Powder characteristics and sintering behavior are given for the nickel aluminide employed in this study to highlight the powder attributes needed for injection molding. Molding parameters, debinding and sintering schedules, along with mechanical properties are presented to indicate the viability of PIM for intermetallics. This approach based on the understanding of key powder characteristics and use of the reactive synthesis powder process may be extended to the successful injection molding of other intermetallic systems.