Abstract
Powder injection molding (PIM) is one of the modern and prospective technologies in processing different materials. We proposed to use bimodal compositions of particles for increasing their content in the final products. A set of model suspension of Al with low-molecular-weight poly (ethylene glycol) as a binder based on theoretical arguments concerning the filling capacity of bimodal suspensions was prepared. Studying the rheological properties of these compositions showed that they demonstrate elasto-viscous behavior with significant plasticity that is favorable for the technological process. Using compositions with bimodal distributions allows for increasing the content of the solid phase up to 75 vol. % for PIM technology, which is significantly higher than the standard practical limit. This rheological approach developed for model formulations was applied to processing compositions containing aluminum oxide as typical ceramics and polyolefines as a binder widely used in technological practice. The obtained sintered ceramic samples have quite acceptable mechanical properties of the usual corundum articles.
Highlights
The powder injection molding (PIM) technology became rather popular in the last few years, due to its possibility to utilize waste and produce rather delicate articles from metals and ceramics
From the fundamental point of view, this technology is based on the rheology of highly concentrated suspensions
In our earlier publications [44,45] it has been shown that there is a concentration range of plasticity where a possibility of irreversible displacement still exists. It would be interesting, and possibly useful, to spread this concept on binary suspensions, as well as to try to obtain articles from such suspensions by PIM from as high concentrated suspensions as it can be possible. This means that the goals of this work are to prepare binary mixtures of the optimal composition that allows for retaining the plasticity up to high concentrations of the filler, to clarify the quantitative characteristics of the rheological properties of such mixtures, to compare their properties with previously studied monodisperse suspensions of similar composition and to form representative articles by the PIM method
Summary
The powder injection molding (PIM) technology became rather popular in the last few years, due to its possibility to utilize waste and produce rather delicate articles from metals and ceramics. This technology is a combination of two areas of manufacturing: polymer injection molding and powder technology. In combination with some additives, provide a possibility of processing the various parts from feedstocks. All components except the powder should be removed after injection molding in order to obtain a metal or ceramic item. Understanding the behavior of such suspensions is necessary for developing this technological process
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