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Process for debinding and sintering metal injection molded parts made with an aqueous binder

A water-based binder, binder technology, applied in the field of debinding and sintering of metal injection molded parts made of water-based binders, can solve problems such as restrictions and environmental problems

Inactive Publication Date: 2001-12-05
RUTGERS THE STATE UNIV OF NEW JERSEY (US)
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Requirement of separate debinder furnaces and different debinder times depending on part size limits this improvement
Also the removal of large amounts of wax / polymer in the form of dangerous flames and VOC emissions both pose environmental concerns

Method used

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  • Process for debinding and sintering metal injection molded parts made with an aqueous binder
  • Process for debinding and sintering metal injection molded parts made with an aqueous binder
  • Process for debinding and sintering metal injection molded parts made with an aqueous binder

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0025] This example illustrates the criticality of the air debinding step prior to sintering in order to prevent excess carbon in the 17-4PH stainless steel alloy. The 17-4PH stainless steel powder purchased from Ultrafine MetalS with a particle size of <20 μm and atomized with argon gas was used to prepare the 17-4PH raw material. 17-4PH powder was mixed with agar (S-100, Frutarom Meer company), water and calcium borate to obtain a composition (wt%) of 92.5% for 17-4PH, 1.7% for agar, 5.7% for water and calcium borate as 0.1% of the composition. Mixing was carried out in a Sigma mixer, the temperature of the mixer was heated to 88° C., mixed for 45 minutes, then the temperature was lowered to 77° C., and the mixing was continued for 45 minutes. After allowing the material to cool to room temperature, chop it with a food processor (Kitchen Aid KSM90) and sieve through a #5 sieve to remove any large and fine pieces. The chopped material is dried to the desired solids content ...

Embodiment 2

[0036] This example describes the criticality of performing an air debinding step prior to sintering a 17-4PH stainless steel alloy to achieve a density of greater than 99% after sintering. Sample preparation and analysis were carried out as in Example 1 with MINITAB. figure 2 Shown are a Barrett plot and a main effects plot with final densities as output. This Barrett plot indicates that, among the factors and levels analyzed in the 16 experiments, the debinder atmosphere is the only important factor for maximum density. Examination of the main effects plot shows that air debinding yields a maximum density of >98%, while hydrogen debinding shows only 90% density.

Embodiment 3

[0038] This example shows the criticality of performing an air debinding step prior to sintering to obtain a tensile elongation of 9% after sintering for a 17-4PH stainless steel alloy heat treated at H1025. Samples were prepared and analyzed as in Example 1 using MINITAB. exist image 3 Shown above is a Barrett plot and main effects plot with tensile elongation as output. This Barrett plot indicates that, among the factors and levels analyzed in the 16 experiments, the debonding atmosphere is the only important factor in order to obtain the maximum tensile elongation. Examination of the main effects plot indicated that air debinding gave a maximum tensile elongation of >10%, whereas hydrogen atmosphere debinding showed only 2% elongation.

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Abstract

A debinding and sintering method is employed to produce consolidated net shape articles from metal powders including 17-4PH stainless steel alloy by metal injection molding using an agar based aqueous binder. The debinding and sintering step can be combined into one cycle to economically produce components for the consumer and aerospace industries.

Description

field of invention [0001] The present invention relates to methods of debinding and sintering of 17-4PH stainless steel and stainless steel parts obtained from metal injection molding powders. More particularly, this invention relates to a debinder and sintering process that yields mechanical properties comparable to cast and forged 17-4PH parts for aerospace or other structural applications. Such parts are produced by the final shape method of metal injection molding, using a water-based raw material binder. Background of the invention [0002] Description of prior art [0003] Precipitation hardening (PH) stainless steel alloys find widespread application in aerospace and other high technology industries due to their wide range of mechanical properties. The yield strength is 75-205ksi, the ultimate strength is 125-220ksi, and the elongation is 1-25%. Common alloys include martensitic 15-5PH, semi-austenitic 17-7PH, and austenitic A-286. Martensitic alloy 17-4PH has a n...

Claims

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Application Information

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IPC IPC(8): B22F3/02B22F3/10B22F3/22C22C33/02
CPCB22F3/22B22F3/225B22F2999/00B22F2998/00B22F3/1021B22F3/101B22F2201/03B22F2201/013
Inventor J·C·拉萨勒B·C·舍尔曼M·S·泽达利斯
Owner RUTGERS THE STATE UNIV OF NEW JERSEY (US)
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