One-piece precursor test coupon for testing material properties of metal injection molded parts and method and apparatus for making such coupons - Patents.com

Abstract

To provide monolithic precursor test coupons for testing material properties of metal-injection-molded components, with reduced risk of damaging the coupons.SOLUTION: A monolithic precursor test coupon (100) includes a first grip portion (110), a second grip portion (112), and an intermediate portion (114), which interconnects the first grip portion (110) and the second grip portion (112). The monolithic precursor test coupon (100) also includes runners (130), which directly interconnect the first grip portion (110) and the second grip portion (112) and not directly connected to the intermediate portion (114). The first grip portion (110), the second grip portion (112), the intermediate portion (114) and the runners (130) are composed of a substance (150) that comprises metal powder and that is in a green state.SELECTED DRAWING: Figure 2A

Description

[Technical field]

[0001] This disclosure relates to one-piece precursor test coupons for testing material properties of metal injection molded parts. [Background technology]

[0002]

[0002] Various structural components are manufactured using metal injection molding (MIM) technology. The MIM process uses a granular feedstock, including powdered metal. Such feedstock is injected into a mold to form a green part that is substantially geometrically similar to the final part, but which may be larger relative to the final part to allow for shrinkage during the subsequent sintering step. The green part is then subjected to debonding, e.g., a heat or solvent-based process, to remove the bonding agent and form a brown part. The brown part is then sintered at high temperatures to form a substantially final metal part.

[0003]

[0003] It is often necessary and / or desirable to quantify certain material properties of MIM manufactured components by testing coupons formed in the same manner and from the same materials as the components of interest. Such test coupons usually have a reduced central cross-sectional area and are sometimes referred to as "dog bone" coupons. When feedstock is injected into a mold during the MIM process to create the test coupon, the reduced central cross-sectional area acts as a restriction that prevents proper flow of feedstock through the reduced area portion of the coupon. When the feedstock injection pressure is increased to overcome the restriction, in some cases the feedstock is extruded too quickly beyond the restriction and the binder is sheared off the feedstock. If the binder is not uniformly distributed throughout the green test coupon after the injection molding process is complete, the coupon may warp during sintering. On the other hand, if the feedstock is extruded too slowly beyond the restriction, the binder will tend to cross-link and solidify the feedstock before injection is complete, preventing further injection.

[0004]

[0004] Because green parts are relatively fragile, long, narrow green parts with reduced central cross-sectional areas cannot survive normal molding injection techniques without damage. Mold release agents are not typically used in MIM processes due to potential raw material contamination issues. Therefore, attempts have been made to increase the number of ejector pins incorporated into the mold to improve the distribution of ejection forces experienced by the green test coupons during the demolding step and reduce the likelihood of damage when the coupons are removed from the mold. However, the long, narrow shape and reduced central cross-sectional area of ​​the coupons require high injection pressures during the MIM process, which can cause bonding agents to flow into the space between the ejector pins and the mold, causing the ejector pins to stick to the mold and making it impossible to eject the coupon from the mold. Furthermore, as mentioned above, long, narrow green parts with reduced central cross-sectional areas, such as green test coupons formed by MIM processes, can warp at high temperatures upon sintering.

[0005]

[0005] Green test coupons formed in the MIM process can also have undesirable "flash", i.e., ridges of excess material formed by the feedstock and penetrating into the mold parting line during the MIM process. Removing flash from long, narrow green parts using conventional manual techniques risks damaging the coupon. Summary of the Invention

[0006]

[0006] Accordingly, an apparatus and method intended to address at least the above-identified concerns would find utility.

[0007]

[0007] Below is a non-exhaustive list of embodiments of the subject matter disclosed herein, which may or may not be claimed.

[0008]

[0008] Disclosed herein is a one-piece precursor test coupon including a first gripping portion, a second gripping portion, and a middle portion interconnecting the first gripping portion and the second gripping portion. The one-piece precursor test coupon also includes a runner that directly interconnects the first gripping portion and the second gripping portion and is not directly connected to the middle portion. The first gripping portion, the second gripping portion, the middle portion, and the runner are made of a material that includes metal powder and is in a green state.

[0009]

[0009] The runners provide a one-piece precursor test coupon with improved stability and inhibit breakage or warping of the first gripping portion, the second gripping portion, and the middle portion during and after the process of forming the one-piece precursor test coupon, such as during one or more of removal from a mold, such as a metal injection molding (MIM) apparatus in the green state, debonding, and sintering. Additionally, because the runners interconnect the first gripping portion and the second gripping portion and are not directly attached to the middle portion, removing the runners during the process of forming the test coupon from the one-piece precursor test coupon reduces the risk of damage to the middle portion and increases the accuracy of subsequent material property testing using the test coupon formed from the one-piece precursor test coupon.

[0010] Also disclosed herein is a metal injection molding (MIM) apparatus for creating a one-piece precursor test coupon. The MIM apparatus includes a mold and defines a mold cavity. The mold cavity includes a first gripping portion cavity and a second gripping portion cavity. The mold cavity also includes a middle portion cavity interconnecting the first gripping portion cavity and the second gripping portion cavity. The mold cavity further includes a runner cavity directly interconnecting the first gripping portion cavity and the second gripping portion cavity and not directly connected to the middle portion cavity. The MIM apparatus additionally includes an injector operable to inject a feedstock material including a metal powder into the mold cavity to form the one-piece precursor test coupon.

[0011]

[0011] The MIM apparatus allows for uniform distribution of feedstock material within the first gripper cavity, the middle cavity, and the second gripper cavity, and may facilitate the formation of a one-piece precursor test coupon in the mold with reduced or eliminated voids and reduced or eliminated shearing of binder contained within the feedstock material along with the metal powder. More specifically, the runner cavity allows a portion of the feedstock material to bypass the flow restriction caused by the middle cavity and backfill downstream portions of the one-piece precursor test coupon. Thus, the bypass flow range provided by the runner cavity allows the formation of a one-piece precursor test coupon with proper distribution and integrity of feedstock material at injection speeds that avoid issues of binder shearing or premature binder cross-linking.

[0012] Additionally disclosed herein is a flash removal tool including a tool body extending along a longitudinal tool axis. The flash removal tool also includes tines projecting from the tool body in a first direction. The flash removal tool further includes an engagement surface located a preselected distance along the longitudinal tool axis from the tines and perpendicular to the longitudinal tool axis. The tines include a shear surface facing in the first direction and positioned an offset distance away from the longitudinal tool axis in a second direction. The first direction and the second direction are orthogonal to each other and define a plane perpendicular to the longitudinal tool axis.

[0013]

[0013] The engagement surfaces are spaced from the tines by a preselected distance such that the tines are longitudinally aligned with the gauge portion when the engagement surfaces engage the integral precursor test coupon. Furthermore, the tines project from the tool body in a first direction and have offset spaced shear surfaces in a second direction such that the tines slide between the runners of the integral precursor test coupon such that the shear surfaces precisely align with the flash on the gauge portion of the integral precursor test coupon. Thus, the flash removal tool facilitates removal of the flash from the gauge portion while the runners are still attached to the integral precursor test coupon without the need for complex alignment procedures or adjustments.

[0014]

[0014] Also disclosed herein is a method of making a test coupon using a mold. The mold defines a mold cavity including a first gripping portion cavity, a second gripping portion cavity, and a middle portion cavity interconnecting the first gripping portion cavity and the second gripping portion cavity. The mold cavity further includes a runner cavity directly interconnecting the first gripping portion cavity and the second gripping portion cavity and not directly connected to the middle portion cavity. The method includes injecting a feedstock material including a metal powder into the mold cavity to form a one-piece precursor test coupon in the mold cavity. The one-piece precursor test coupon includes a first gripping portion having a shape complementary to a shape of the first gripping portion cavity and a second gripping portion having a shape complementary to a shape of the second gripping portion cavity. The one-piece precursor test coupon also includes a middle portion having a shape complementary to the shape of the middle portion cavity and runners each having a shape complementary to a corresponding shape of the runner cavity. The method also includes removing the runners from the one-piece precursor test coupon.

[0015]

[0015] The method allows for uniform distribution of raw material within the first gripper cavity, the middle portion cavity, and the second gripper cavity, and may facilitate the formation of a one-piece precursor test coupon in a mold with reduced or eliminated voids and reduced or eliminated shearing of binder contained in the raw material with the metal powder. More specifically, the runner cavity allows a portion of the raw material to bypass the flow restriction caused by the middle portion cavity and backfill downstream portions of the one-piece precursor test coupon. Thus, the bypass flow range provided by the runner cavity allows the formation of a one-piece precursor test coupon with proper distribution and integrity of raw material at injection speeds that avoid issues of binder shearing or premature binder cross-linking. Removal of the runner from the one-piece precursor test coupon leaves the first gripper portion, the middle portion, and the second gripper portion of the test coupon for material property testing, such as in a tensile testing machine.

[0016] Also disclosed herein is a method of removing flash from a gauge portion of a one-piece precursor test coupon using a flash removal tool. The flash removal tool includes a tool body extending along a longitudinal tool axis. The flash removal tool also includes tines and an engagement surface spaced from the tines along the longitudinal tool axis. The tines project from the tool body in a first direction and include a shear surface facing in the first direction and offset away from the longitudinal tool axis in a second direction. The first direction and the second direction are orthogonal to each other and define a plane perpendicular to the longitudinal tool axis. The method includes coupling the engagement surface of the flash removal tool to a first precursor coupon end of the one-piece precursor test coupon. The method also includes orienting the longitudinal tool axis parallel to a longitudinal axis of symmetry of the one-piece precursor test coupon, with the shear surface coinciding with the longitudinal direction.

[0017]

[0017] By having the teeth protruding from the tool body in a first direction and having offset, spaced shear surfaces in a second direction, when the engagement surface of the flash removal tool is coupled to the first precursor coupon end and the longitudinal tool axis is oriented parallel to the longitudinal axis of symmetry of the integral precursor test coupon, the shear surfaces are longitudinally aligned with the flash, facilitating removal of the flash from the gauge portion at increased speed without the need for complex alignment procedures or adjustments.

[0018] Having thus generally described one or more embodiments of the present disclosure, reference is now made to the accompanying drawings, which are not necessarily drawn to scale and in which like reference characters indicate the same or similar parts throughout the several views. [Brief description of the drawings]

[0019] [Figure 1A] FIG. 1 is a block diagram of an integrated precursor test coupon according to one or more examples of the present disclosure. [Figure 1B]

[0020] FIG. 1 is a block diagram of a metal injection molding apparatus according to one or more examples of the present disclosure. [Figure 1C]

[0021] FIG. 1 is a block diagram of a flash removal tool according to one or more examples of the present disclosure. [Figure 2A]

[0022] FIG. 1B is a schematic perspective view of the unitary precursor test coupon of FIG. 1A having three runners, according to one or more examples of the present disclosure. [Figure 2B]

[0023] FIG. 1B is a schematic perspective view of the unitary precursor test coupon of FIG. 1A having two runners, in accordance with one or more examples of the present disclosure. [Figure 2C]

[0024] FIG. 1B is a schematic perspective view of the unitary precursor test coupon of FIG. 1A having four runners, according to one or more examples of the present disclosure. [Figure 3A]

[0025] 1B is a schematic elevational view of the unitary precursor test coupon of FIG. 1A having respective curvatures adjacent respective gripping portions, in accordance with one or more examples of the present disclosure. FIG. [Figure 3B]

[0026] FIG. 1B is a schematic elevational view of the unitary precursor test coupon of FIG. 1A having a continuous curvature between respective gripping portions, in accordance with one or more examples of the present disclosure. [Figure 4]

[0027] 1B is a schematic elevational view of a pair of respective intermediate portions of the unitary precursor test coupons of FIG. 1A having notches, in accordance with one or more examples of the present disclosure. FIG. [Diagram 5]

[0028] FIG. 1B is a schematic elevational view of the unitary precursor test coupon of FIG. 1A, in accordance with one or more examples of the present disclosure. [Figure 6]

[0029] FIG. 6 is a schematic cross-sectional view of a portion of the integral precursor test coupon of FIG. 5, in accordance with one or more examples of the present disclosure. [Figure 7]

[0030] FIG. 1C is a schematic elevational partial cross-sectional view of the metal injection molding apparatus of FIG. 1B in accordance with one or more examples of the present disclosure. [Figure 8A]

[0031] FIG. 1C is a schematic perspective view of the metal injection molding apparatus of FIG. 1B having three runner cavities, according to one or more examples of the present disclosure. [Figure 8B]

[0032] FIG. 1C is a schematic perspective exploded view of the metal injection molding apparatus of FIG. 1B having three runner cavities, in accordance with one or more examples of the present disclosure. [Figure 8C]

[0033] FIG. 1C is a schematic perspective view of a portion of the metal injection molding apparatus of FIG. 1B including an ejector pin, in accordance with one or more examples of the present disclosure. [Figure 8D]

[0034] FIG. 1C is a schematic cross-sectional elevation view of a portion of the metal injection molding apparatus of FIG. 1B including an ejector pin, in accordance with one or more examples of the present disclosure. [Figure 8E]

[0035] FIG. 1C is a schematic perspective view of the metal injection molding apparatus of FIG. 1B having four runner cavities, according to one or more examples of the present disclosure. [Figure 8F]

[0036] FIG. 1C is a schematic perspective view of the metal injection molding apparatus of FIG. 1B having two runner cavities, according to one or more examples of the present disclosure. [Figure 9]

[0037] FIG. 1B is a schematic perspective view of a test coupon formed from the unitary precursor test coupon of FIG. 1A, in accordance with one or more examples of the present disclosure. [Figure 10A]

[0038] 1D is a schematic perspective view of the flash removal tool of FIG. 1C extending longitudinally on either side of the tines, according to one or more examples of the present disclosure. [Figure 10B]

[0039] 1D is a schematic perspective view of the flash removal tool of FIG. 1C extending longitudinally on one side of the tines, according to one or more examples of the present disclosure. FIG. [Figure 10C]

[0040] 1C being applied to the integral precursor test coupon of FIG. 1A, shown in partial cross-section, in accordance with one or more examples of the present disclosure. FIG. [Figure 10D]

[0041] FIG. 1C is a schematic perspective view of the flash removal tool of FIG. 1C applied to the integral precursor test coupon of FIG. 1A in accordance with one or more examples of the present disclosure. [Figure 10E]

[0042] 1C is a schematic cross-sectional elevation view of the flash removal tool of FIG. 1C applied to the integral precursor test coupon of FIG. 1A in accordance with one or more examples of the present disclosure. [Figure 11A]

[0043] 11B and 11C collectively illustrate a block diagram of a method, according to one or more examples of the present disclosure, for creating a test coupon using the apparatus of FIG. 1B, according to one or more examples of the present disclosure. [Figure 11B] 11A and 11C collectively illustrate a block diagram of a method, according to one or more examples of the present disclosure, for creating a test coupon using the apparatus of FIG. 1B, according to one or more examples of the present disclosure. [Figure 11C] 11A and 11B collectively illustrate a block diagram of a method, according to one or more examples of the present disclosure, for creating a test coupon using the apparatus of FIG. 1B, according to one or more examples of the present disclosure. [Figure 12A]

[0044] Collectively with Figures 12B, 12C, and 12D, a block diagram of a method, according to one or more examples of the present disclosure, for removing flash from a gauge portion of an integrated precursor test coupon using the apparatus of Figure 1C, according to one or more examples of the present disclosure. [Figure 12B] Collectively with Figures 12A, 12C, and 12D, a block diagram of a method, according to one or more examples of the present disclosure, for removing flash from a gauge portion of an integrated precursor test coupon utilizing the apparatus of Figure 1C, according to one or more examples of the present disclosure. [Figure 12C] Collectively with Figures 12A, 12B, and 12D, a block diagram of a method, according to one or more examples of the present disclosure, for removing flash from a gauge portion of an integrated precursor test coupon utilizing the apparatus of Figure 1C, according to one or more examples of the present disclosure. [Figure 12D] Collectively with Figures 12A, 12B, and 12C, a block diagram of a method, according to one or more examples of the present disclosure, for removing flash from a gauge portion of an integrated precursor test coupon utilizing the apparatus of Figure 1C, according to one or more examples of the present disclosure. [Figure 13]

[0045] FIG. 1 is a block diagram of an aircraft manufacturing and service method. [Figure 14]

[0046] FIG. 1 is a schematic diagram of an aircraft. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020]

[0047] In the above figures 1A, 1B and 1C, where solid lines are present connecting various elements and / or components, these solid lines may represent mechanical, electrical, fluid, optical, electromagnetic and other connections and / or combinations thereof. In this document, "coupled" means directly and indirectly associated. For example, member A may be directly associated with member B, or indirectly associated, for example, via another member C. It will be understood that not all relationships between various disclosed elements are necessarily represented. Thus, there may be connections other than those shown in the block diagram. Where dashed lines are present connecting blocks showing various elements and / or components, these dashed lines represent connections similar in function and purpose to those represented by the solid lines, but the connections represented by the dashed lines may be either selectively provided or related to alternative embodiments of the present disclosure. Similarly, where dashed elements and / or components are present, they represent alternative embodiments of the present disclosure. One or more elements shown with solid and / or dashed lines may be omitted from a particular embodiment without departing from the scope of the present disclosure. Environmental elements, if present, are represented with dotted lines. For clarity, virtual (imaginary) elements may also be shown. Those skilled in the art will understand that some of the features shown in Figures 1A, 1B, and 1C may be combined in various ways (even if one or more such combinations are not expressly stated herein) without necessarily including other features described in Figures 1A, 1B, and 1C, other figures, and / or the accompanying disclosure. Similarly, additional features, not limited to the examples presented, may be combined with some or all of the features shown and described herein.

[0021]

[0048] In the above figures 11A, 11B, 11C, 12A, 12B, 12C and 12D, the blocks may represent steps and / or portions thereof, and the lines connecting various blocks do not imply any particular order or dependency of these steps or portions thereof. Blocks shown with dashed lines represent alternative steps and / or portions thereof. Where dashed lines connect various blocks, the dashed lines represent alternative dependencies of steps or portions thereof. It will be understood that not all dependencies between the various steps disclosed are necessarily represented. Figures 11A, 11B, 11C, 12A, 12B, 12C and 12D and the accompanying disclosure describing steps of one or more methods set forth herein should not be construed as necessarily dictating the order in which steps should be performed. Rather, even if a certain example order is shown, it should be understood that the sequence of steps may be modified, where appropriate. Thus, certain steps may be performed in a different order or simultaneously. In addition, one of ordinary skill in the art will recognize that not all steps listed need to be performed.

[0022]

[0049] In the following description, numerous specific details are set forth to provide a thorough understanding of the disclosed concepts, although the concepts may be practiced without some or all of these details. In other instances, details of well-known devices and / or processes are omitted to avoid unnecessarily obscuring the disclosure. While some concepts will be described in conjunction with specific examples, it will be understood that these examples are not intended to be limiting.

[0023]

[0050] Unless otherwise indicated, the terms "first," "second," etc. are used herein merely as labels and are not intended to impose any sequential, positional, or hierarchical requirements on the items they refer to. Moreover, a reference to, for example, a "second" item does not require or preclude the presence of, for example, a "first" or lower numbered item and / or, for example, a "third" or higher numbered item.

[0024]

[0051] A reference herein to "one or more embodiments" means that one or more of the features, structures, or characteristics described in connection with the embodiment are included in at least one embodiment. The phrase "one or more embodiments" appearing in various places herein may or may not refer to the same embodiment.

[0025]

[0052] ] In this document, a system, device, structure, article, element, component, or hardware that is "configured to" perform a particular function is not in fact capable of performing that particular function without any modification, but rather may perform that particular function after further modification. In other words, a system, device, structure, article, element, component, or hardware that is "configured to" perform a particular function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing that particular function. As used herein, the phrase "configured to" means that there are characteristics of the system, device, structure, article, element, component, or hardware that enable the system, device, structure, article, element, component, or hardware to perform the particular function without further modification. In this disclosure, a system, device, structure, article, element, component, or hardware that is described as "configured to" perform a particular function may additionally or alternatively be described as "adapted to" and / or "operative to" perform that function.

[0026]

[0053] Illustrative, non-exhaustive examples of the subject matter according to the present disclosure are provided below, which may or may not be claimed.

[0027]

[0054] 1A and 1B in general, and for example, in particular in FIGS. 2A, 2B, and 2C, a one-piece precursor test coupon 100 is disclosed. The one-piece precursor test coupon 100 includes a first gripping portion 110, a second gripping portion 112, and a middle portion 114 interconnecting the first gripping portion 110 and the second gripping portion 112. The one-piece precursor test coupon 100 also includes a runner 130 that directly interconnects the first gripping portion 110 and the second gripping portion 112 and is not directly connected to the middle portion 114. The first gripping portion 110, the second gripping portion 112, the middle portion 114, and the runner 130 are comprised of a material 150 that includes metal powder 748 and is in a green state. The above subject matter of this paragraph characterizes Example 1 of the present disclosure.

[0028]

[0055] ] The runners 130 provide the one-piece precursor test coupon 100 with increased stability and inhibit breakage or warping of the first gripping portion 110, the second gripping portion 112, and the middle portion 114 during and after the process of forming the one-piece precursor test coupon 100, such as during one or more of removal from a mold, debonding, and sintering, such as a green state metal injection molding (MIM) apparatus 700 (shown in FIG. 8A ). Additionally, because the runners 130 interconnect the first gripping portion 110 and the second gripping portion 112, and are therefore not directly attached to the middle portion 114, removing the runners 130 during the process of forming the test coupon 900 (shown in FIG. 9 ) from the one-piece precursor test coupon 100 reduces the risk of damage to the middle portion 114 and enhances the accuracy of subsequent material property testing using the test coupon 900 formed from the one-piece precursor test coupon 100.

[0029]

[0056] 1A generally, and, for example, with particular reference to Figures 2A, 2B, and 2C, a first gripping portion 110, an intermediate portion 114, and a second gripping portion 112, which extend consecutively along a longitudinal axis of symmetry 106 from a first precursor coupon end 102 to a second precursor coupon end 104, together define a precursor coupon body 108. The above subject matter of this paragraph characterizes Example 2 of the present disclosure, which also includes subject matter according to Example 1 above.

[0030]

[0057] With the first gripping portion 110, the intermediate portion 114, and the second gripping portion 112 extending continuously along the longitudinal axis of symmetry 106 from the first precursor coupon end 102 to the second precursor coupon end 104, a test coupon 900 (not shown in FIG. 9) can be formed in approximately net shape from the one-piece precursor test coupon 100 by removing the runner 130.

[0031]

[0058] 1A in general, and, for example, in particular, with reference to Figures 2A, 2B, and 2C, first gripping portion 110 and second gripping portion 112 have the same order of symmetry about longitudinal axis of symmetry 106. The above subject matter of this paragraph characterizes Example 3 of the present disclosure, which also includes subject matter according to Example 2 above.

[0032]

[0059] Due to the first gripping portion 110 and the second gripping portion 112 having the same order of symmetry around the longitudinal axis of symmetry 106, the first gripping portion 110 and the second gripping portion 112 can be mounted onto standard off-the-shelf material property testing equipment (e.g., a tensile testing machine, not shown) with little or no modification required.

[0033]

[0060] 1A in general, and, for example, in particular, with reference to FIGS. 2A, 2B, and 2C, intermediate portion 114 includes a gauge portion 120. Gauge portion 120 has a gauge portion cross-section perpendicular to longitudinal axis of symmetry 106. The gauge portion cross-section is smaller than the cross-sectional area perpendicular to longitudinal axis of symmetry 106 of all portions of intermediate portion 114 other than gauge portion 120. The above subject matter in this paragraph characterizes Example 4 of the present disclosure, which also includes subject matter according to Examples 2 or 3 above.

[0034]

[0061] The gauge portion 120 provides the location of the smallest cross section along a test coupon 900 (shown in FIG. 9 ) formed from the unitary precursor test coupon 100. The gauge portion 120 therefore represents a likely failure point of the test coupon 900 during material property testing, and the cross section of the gauge portion 120 can be used along with applied force measurements from standard off-the-shelf material property testing equipment (e.g., a tensile testing machine, not shown) to calculate material properties of the material of the test coupon 900.

[0035]

[0062] 1A generally, and for example, with particular reference to FIG. 3A , surface 116 of intermediate portion 114 has a linear contour in a plane containing longitudinal axis of symmetry 106 that defines a first curvature 302 adjacent first gripping portion 110, a second curvature 304 adjacent second gripping portion 112, and a gauge portion 120 over a gauge length 122 between first curvature 302 and second curvature 304. The above subject matter of this paragraph characterizes Example 5 of the present disclosure, which also includes subject matter according to Example 4 above.

[0036]

[0063] The first curvature 302 adjacent the first gripping portion 110 and the second curvature 304 adjacent the second gripping portion 112, and the linear contour located between the first curvature 302 and the second curvature 304, and defining the gage portion 120, facilitates formation of the gage portion 120 with a preselected stress profile and simplifies calculation of material properties from test results of the test coupon 900 (shown in FIG. 9 ). In some examples, the first curvature 302 is formed with a first radius of curvature 312 and the second curvature 304 is formed with a second radius of curvature 314 that is substantially identical to the first radius of curvature 312.

[0037]

[0064] 1A generally, and for example, with particular reference to FIG. 3B, surface 116 of intermediate portion 114 has a continuous curvature 306 between first gripping portion 110 and second gripping portion 112, such that gauge portion 120 lies in a plane perpendicular to longitudinal axis of symmetry 106. The above subject matter in this paragraph characterizes Example 6 of the present disclosure, which also includes subject matter according to Example 4 above.

[0038]

[0065] The continuous curvature 306 between the first gripping portion 110 and the second gripping portion 112 such that the gauge portion 120 lies in a plane perpendicular to the longitudinal axis of symmetry 106 facilitates formation of the gauge portion 120 with a preselected stress profile, further provides a relatively narrow region where the test coupon 900 (shown in FIG. 9 ) is expected to fail during certain material property testing methods, and simplifies calculation of material properties from the test results of the test coupon 900. In some examples, the continuous curvature 306 is formed with a single, constant radius of curvature 316 between the first gripping portion 110 and the second gripping portion 112.

[0039]

[0066] 1A in general, and for example, in particular, FIG. 4, intermediate portion 114 further includes notch 400, which includes gauge portion 120. The above subject matter of this paragraph characterizes Example 7 of the present disclosure, which also includes subject matter according to any one of Examples 4 through 6 above.

[0040]

[0067] The notch 400 further provides a relatively narrow area where the test coupon 900 (shown in FIG. 9 ) is expected to fail during a certain material property testing method, and also forms the gauge portion 120 with a preselected stress profile, simplifying the calculation of material properties from the test results of the test coupon 900.

[0041]

[0068] 1A in general, and for example, in particular, with reference to FIG. 4, the notch 400 has, in a plane containing the longitudinal axis of symmetry 106, one of an angled contour 402 along the longitudinal axis of symmetry 106, an arcuate contour 404 along the longitudinal axis of symmetry 106, or a rectangular contour 406 along the longitudinal axis of symmetry 106. The above subject matter in this paragraph characterizes Example 8 of the present disclosure, which also includes subject matter according to Example 7 above.

[0042]

[0069] The notch 400 having one of an angled contour 402, an arcuate contour 404, or a rectangular contour 406 further facilitates forming the gauge portion 120 with a preselected stress profile and simplifies the calculation of material properties from the test results of the test coupon 900 (shown in FIG. 9 ).

[0043]

[0070] 1A in general, and e.g., with particular reference to FIG. 4, notch 400 is symmetrical about longitudinal axis of symmetry 106. The above subject matter in this paragraph characterizes Example 9 of the present disclosure, which also includes subject matter according to Examples 7 or 8 above.

[0044]

[0071] The symmetry of the notch 400 about the longitudinal axis of symmetry 106 facilitates the formation of a gauge portion 120 having a preselected symmetric stress profile and simplifies the calculation of certain material properties from the test results of the test coupon 900 (shown in FIG. 9 ).

[0045]

[0072] 1A in general, and, for example, in particular, with reference to FIG. 4, notch 400 is not symmetrical about longitudinal axis of symmetry 106. The above subject matter in this paragraph characterizes Example 10 of the present disclosure, which also includes subject matter according to Examples 7 or 8 above.

[0046]

[0073] The lack of symmetry of notch 400 about longitudinal axis of symmetry 106 facilitates the formation of gauge section 120 having preselected stress concentrations in the areas of lack of symmetry and simplifies the calculation of certain material properties from the test results of test coupons 900 (shown in FIG. 9 ).

[0047]

[0074] 1A in general, and with particular reference to, for example, Figures 2A, 2B, and 2C, the runners of one adjacent pair of runners 130, and the runners of any other adjacent pair of runners 130, have equal angular separation about the longitudinal axis of symmetry 106. The above subject matter of this paragraph characterizes Example 11 of the present disclosure, which also includes subject matter according to any one of Examples 2 through 10 above.

[0048]

[0075] Runners 130 having equal angular separation about the longitudinal axis of symmetry 106 facilitate increased stability of the unitary precursor test coupon 100 .

[0049]

[0076] 1A in general, and, for example, in particular, with reference to FIG. 5, the overall length 500 of the unitary precursor test coupon 100 measured along the longitudinal axis of symmetry 106 is between about 4 inches and about 12 inches, and the length 514 of the intermediate portion 114 is between about 1 inch and about 6 inches. The above subject matter of this paragraph characterizes Example 12 of the present disclosure, which also includes subject matter according to any one of Examples 2 through 11 above.

[0050]

[0077] In some examples, with overall lengths 500 and lengths 514 in the disclosed ranges, test coupons 900 (shown in FIG. 9 ) formed from integral precursor test coupons 100 can be accurately tested on standard off-the-shelf material property testing equipment (e.g., a tensile testing machine, not shown) with little or no modification required.

[0051]

[0078] 1A in general, and, for example, in particular, with reference to FIG. 5, the gripping diameter 510 of each of the first and second gripping portions 110 and 112 is between about 0.1 inches and about 1.2 inches, and the minimum diameter 515 of the intermediate portion 114 is between about 0.2 inches and about 0.6 inches. The above subject matter of this paragraph characterizes Example 13 of the present disclosure, which also includes subject matter according to Example 12 above.

[0052]

[0079] In some examples, the disclosed range of gripping diameters 510 allows test coupons 900 (shown in FIG. 9 ) formed from integral precursor test coupons 100 to be accurately tested on standard off-the-shelf material property testing equipment (e.g., a tensile testing machine, not shown) with little or no modification required.

[0053]

[0080] 1A in general, and for example, in particular with reference to FIG. 5, each of the runners 130 has a radius of curvature 530, in a plane containing the longitudinal axis of symmetry 106, of between about 7.6 cm (3 inches) and about 28.0 cm (11 inches). The above subject matter of this paragraph characterizes Example 14 of the present disclosure, which also includes subject matter according to Examples 12 or 13 above.

[0054]

[0081] In some examples, the radius of curvature 530 in the disclosed range provides sufficient separation between the runner 130 and the gauge portion 120 such that the flash 180 (shown in FIG. 10E) can be removed from the gauge portion 120 before the runner 130 is removed from the integral precursor test coupon 100 to form a test coupon 900 (shown in FIG. 9).

[0055]

[0082] 1A in general, and, for example, in particular, with reference to FIGS. 5 and 6, each of the runners 130 defines a runner thickness 531 measured at a plane intersecting the intermediate portion 114. The runner thickness 531 is between about 0.1 inches and about 0.6 inches. The above subject matter of this paragraph characterizes Example 15 of the present disclosure, which also includes subject matter according to any one of Examples 12 through 14 above.

[0056]

[0083] In some examples, with a runner thickness 531 in the disclosed range, the runner 130 can provide structural stability to the integral precursor test coupon 100 and resist cracking or warping of the integral precursor test coupon 100 in the green state during one or more of removal from a mold, such as mold 800 (shown in FIG. 8A), unbonding, and sintering.

[0057]

[0084] 1A in general, and for example, in particular, FIG. 2A, the number of runners 130 is three. The above-mentioned subject matter of this paragraph characterizes Example 16 of the present disclosure, which also includes the subject matter according to any one of Examples 1 to 15 above.

[0058]

[0085] In some examples, with the number of runners 130 being three, the runners 130 can provide structural stability to the one-piece precursor test coupon 100 and resist cracking or warping of the one-piece precursor test coupon 100 in the green state during one or more of removal from a mold, such as mold 800 (shown in FIG. 8A), debonding, and sintering.

[0059]

[0086] 1A in general, and for example, in particular, with reference to FIG. 2B, the number of runners 130 is two. The above-mentioned subject matter of this paragraph characterizes Example 17 of the present disclosure, which also includes the subject matter according to any one of Examples 1 to 15 above.

[0060]

[0087] In some examples, the number of runners 130 is two, which allows the runners 130 to provide structural stability to the one-piece precursor test coupon 100 and resist cracking or warping of the one-piece precursor test coupon 100 in the green state during one or more of removal from a mold, such as mold 800 (shown in FIG. 8A), debonding, and sintering.

[0061]

[0088] 1A in general, and, for example, in particular, FIG. 2C, the number of runners 130 is four. The above-mentioned subject matter of this paragraph characterizes Example 18 of the present disclosure, which also includes the subject matter according to any one of Examples 1 to 15 above.

[0062]

[0089] In some examples, with the number of runners 130 being four, the runners 130 can provide structural stability to the integral precursor test coupons 100 and resist cracking or warping of the integral precursor test coupons 100 during one or more of removal from a mold, such as mold 800 (shown in FIG. 8A), unbonding, and sintering in the green state.

[0063]

[0090] 1A in general, and with particular reference to, for example, FIGS. 5 and 6, the number of runners 130 is three or more, and the runner width 533 increases in the radial direction 534 away from the intermediate portion 114. The above subject matter of this paragraph characterizes Example 19 of the present disclosure, which also includes subject matter according to any one of Examples 1 to 15 above.

[0064]

[0091] In some examples, the runner width 533, which increases in the radial direction 534, allows the one-piece precursor test coupon 100 to be removed from the mold 800 (shown in FIG. 8A ) along a partial plane of the mold 800 without interference from the mold 800, while the runners 130 can provide structural stability to the one-piece precursor test coupon 100 and resist cracking or warping of the one-piece precursor test coupon 100 during one or more of removal from the mold 800 in the green state, unbonding, and sintering.

[0065]

[0092] 1A in general, and with particular reference to, for example, FIGS. 5 and 6, each of the runners 130 is spaced from the intermediate portion 114 by a gap 532 along the entire extent of the intermediate portion 114. The above subject matter of this paragraph characterizes Example 20 of the present disclosure, which also includes subject matter according to any one of Examples 1 through 19 above.

[0066]

[0093] The gap 532 reduces the risk of damage to the intermediate portion 114 during the process of removing the runner 130 from the unitary precursor test coupon 100 to form the test coupon 900 (shown in FIG. 9).

[0067]

[0094] 1B in general, and, for example, in particular with reference to FIG. 7 and FIGS. 8A, 8B, 8E, and 8F, a metal injection molding (MIM) apparatus 700 for producing a one-piece precursor test coupon 100 is disclosed. The MIM apparatus 700 includes a mold 800 defining a mold cavity 808. The mold cavity 808 includes a first gripping portion cavity 810 and a second gripping portion cavity 812. The mold cavity 808 also includes a middle portion cavity 814 that interconnects the first gripping portion cavity 810 and the second gripping portion cavity 812. The mold cavity 808 further includes a runner cavity 830 that directly interconnects the first gripping portion cavity 810 and the second gripping portion cavity 812, and that is not directly connected to the middle portion cavity 814. The MIM apparatus 700 additionally includes an injector 701 operable to inject a feedstock 750 including metal powder 748 into the mold cavity 808 to create a unitary precursor test coupon 100. The above subject matter of this paragraph characterizes Example 21 of the present disclosure.

[0068]

[0095] The MIM apparatus 700 allows for uniform distribution of the feedstock material 750 within the first gripper portion cavity 810, the middle portion cavity 814, and the second gripper portion cavity 812 to reduce or eliminate voids and further reduce or eliminate shearing of the binder 749 contained within the feedstock material 750 along with the metal powder 748 to facilitate the formation of the unitary precursor test coupon 100 in the mold 800. More specifically, the runner cavity 830 allows a portion of the feedstock material 750 to bypass the flow restriction caused by the middle portion cavity 814 and backfill the downstream portion of the unitary precursor test coupon 100 (shown in FIG. 1A ). Thus, the bypass flow range provided by the runner cavity 830 allows for the formation of the unitary precursor test coupon 100 with proper distribution and integrity of the feedstock material 750 at injection speeds that avoid issues of binder shearing or premature binder cross-linking.

[0069]

[0096] 1B in general, and, for example, in particular, in Figures 8A, 8B, 8E, and 8F, mold 800 includes mold sections 860 that are formed when assembled together to define mold cavity 808. The above subject matter of this paragraph characterizes Example 22 of the present disclosure, which also includes subject matter according to Example 21 above.

[0070]

[0097] Mold section 860 allows for disassembly of mold 800 and facilitates extraction of unitary precursor test coupons 100 (shown in FIG. 1A) from mold 800 after the injection process is completed.

[0071]

[0098] 1B in general, and in particular, for example, in FIGS. 8A, 8B, and 8E, the number of runner cavities 830 is three or more, and the mold sections 860 each include two parting faces 870. Each of the parting faces 870 of one of the mold sections 860 is formed to abut a single one of the parting faces 870 of another one of the mold sections 860 when the mold sections 860 are assembled together. Each of the runner cavities 830 is defined between exactly two mold sections 860. The above-mentioned subject matter of this paragraph characterizes Example 23 of the present disclosure, which also includes the subject matter according to Example 22 above.

[0072]

[0099] In examples where the number of runner cavities 830 is three or more, each of the runner cavities 830 is defined precisely between two mold sections 860, thereby reducing or eliminating interference of the runner 130 (shown in FIG. 1A ) with the mold sections 860 during disassembly of the mold sections 860 to remove the integral precursor test coupons 100.

[0073]

[0100] 1B in general, and, for example, with particular reference to Figures 8A, 8B, 8E, and 8F, the number of mold sections 860 is equal to the runner cavities 830. The above subject matter of this paragraph characterizes Example 24 of the present disclosure, which also includes subject matter according to Examples 22 or 23 above.

[0074]

[0101] Mold sections 860 equal in number to the runner cavities 830 are the minimum number of mold sections 860 that enable the runner cavities 830 to be defined between each pair of mold sections 860, and reduce or eliminate interference between the mold sections 860 and the runners 130 (shown in FIG. 1A) formed within the runner cavities 830 during disassembly of the mold sections 860 to remove the integral precursor test coupons 100.

[0075]

[0102] 1B in general, and particularly, for example, in FIGS. 8B, 8C, and 8D, at least one of the mold sections 860 includes a mold cavity wall 866 oriented to define a boundary of the mold cavity 808, and a pin chamber 862 defined in the at least one of the mold sections 860 and dependent on the mold cavity wall 866. The MIM apparatus 700 further includes an ejector pin 850 coupled to the pin chamber 862 and collectively selectively movable between a retracted position relative to the pin chamber 862 and an extended position relative to the pin chamber 862. The ejector pin 850 includes a pin head 852 having a tapered lower surface 854 and an upper surface 856 adjacent the tapered lower surface 854. In the retracted position, the ejector pin 850 is received within the pin chamber 862 such that the upper surface 856 of the pin head 852 is flush with the mold cavity wall 866. In the extended position, ejector pin 850 extends from pin chamber 862 such that pin head 852 is spaced from mold cavity wall 866. The above subject matter of this paragraph characterizes Example 25 of the present disclosure, which also includes subject matter according to any one of Examples 22 to 24 above.

[0076]

[0103] The ejector pins 850, movable from a retracted position to an extended position, facilitate separation of the integral precursor testing coupons 100 from the mold sections 860 after the mold sections 860 are disassembled to remove the integral precursor testing coupons 100. More specifically, moving the ejector pins 850 from a retracted position to an extended position pushes the integral precursor testing coupons 100 away from the mold cavity walls 866.

[0077]

[0104] 1B generally, and, for example, with reference to Figures 8A-8F in particular, upper surface 856 of pin head 852 is contoured to match the local contour of mold cavity wall 866. The above subject matter of this paragraph characterizes Example 26 of the present disclosure, which also includes subject matter according to Example 25 above.

[0078]

[0105] The top surface 856 of the pin head 852 in the retracted position is contoured to match the local contour of the mold cavity wall 866, which facilitates reducing or eliminating defects imprinted by the ejector pin 850 on the surface of the integral precursor test coupon 100 during the MIM process.

[0079]

[0106] 1B generally, and e.g., with particular reference to Figures 7 and 8A-8F, pin chamber 862 includes a tapered portion 864 contoured to receive in direct sealing contact tapered underside 854 of pin head 852 when ejector pin 850 is in the retracted position. The above subject matter in this paragraph characterizes Example 27 of the present disclosure, which also includes subject matter according to Examples 25 or 26 above.

[0080]

[0107] Tapered portion 864 of pin chamber 862 is contoured to receive tapered underside 854 of pin head 852, which facilitates creating a positive seal between pin head 852 and mold cavity wall 866 when injection pressure is applied by MIM apparatus 700. More specifically, when ejector pin 850 is in the retracted position, the positive pressure within mold cavity 808 acts against pin head 852, tending to press ejector pin 850 deeper into pin chamber 862, such that the greater the pressure within mold cavity 808, the better the seal formed between tapered underside 854 and tapered portion 864 of pin chamber 862. Thus, the tapered portion 864 of the pin chamber 862 tends to reduce or eliminate the possibility that when the MIM apparatus 700 applies pressure to the mold cavity 808, the bonding agent 749 will penetrate between the pin head 852 and the mold cavity wall 866, causing the ejector pin 850 to become stuck in a retracted position, thereby making it impossible to eject the integral precursor test coupon 100.

[0081]

[0108] 1B in general, and in particular, for example, in Figures 8A and 8B, the number of runner cavities 830 is three. The above-mentioned subject matter of this paragraph characterizes Example 28 of the present disclosure, which also includes subject matter according to any one of Examples 21 to 27 above.

[0082]

[0109] With the number of runner cavities 830 being three, the one-piece precursor testing coupon 100 is formed with three runners 130, which provides more effective backfilling of the one-piece precursor testing coupon 100 and adds stability to the one-piece precursor testing coupon 100 formed within the mold cavity 808 compared to having a number of runner cavities 830 less than three.

[0083]

[0110] 1B in general, and in particular, for example, in FIG. 8F, the number of runner cavities 830 is two. The above-mentioned subject matter of this paragraph characterizes Example 29 of the present disclosure, which also includes the subject matter according to any one of Examples 21 to 27 above.

[0084]

[0111] With the number of runner cavities 830 being two, the mold 800 can be assembled from only two mold sections 860, resulting in a simpler mold design compared to having three or more runner cavities 830.

[0085]

[0112] 1B in general, and for example, in particular with reference to FIG. 8E, the number of runner cavities 830 is four. The above-mentioned subject matter of this paragraph characterizes Example 30 of the present disclosure, which also includes the subject matter according to any one of Examples 21 to 27 above.

[0086]

[0113] With the number of runner cavities 830 being four, the one-piece precursor testing coupon 100 is formed with four runners 130, which provides more effective backfilling of the one-piece precursor testing coupon 100 and adds stability to the one-piece precursor testing coupon 100 formed within the mold cavity 808 compared to having a number of runner cavities 830 less than four.

[0087]

[0114] 1B in general, and, for example, in particular with reference to Figures 7, 8A, 8B, 8E, and 8F, mold 800 further defines a sacrificial cavity 840 in downstream fluid communication with mold cavity 808. The above subject matter of this paragraph characterizes Example 31 of the present disclosure, which also includes subject matter according to any one of Examples 21 through 30 above.

[0088]

[0115] The sacrificial cavity 840 provides a space where impurities and / or air initially present in the mold cavity 808 and / or feedstock material 750 can be evacuated from the mold cavity 808 at a downstream location as additional amounts of feedstock material 750 continue to be injected into the mold cavity 808 at an upstream location. For example, the feedstock material 750 may initially be at a temperature that causes the bonding agent 749 to partially melt from the feedstock material 750 (which would undesirably alter the material properties of the unitary precursor test coupon 100). An initial portion of the feedstock material 750 can be pushed through the mold cavity 808 and into the sacrificial cavity 840 as the temperature of the feedstock material 750 is adjusted, filling the mold cavity 808 with feedstock material 750 with reduced or eliminated melting of the bonding agent 749.

[0089]

[0116] 1B in general, and, for example, in particular with reference to Figures 7, 8A, 8B, 8E, and 8F, downstream end 842 of sacrificial cavity 840 is closed. The above subject matter of this paragraph characterizes Example 32 of the present disclosure, which also includes subject matter according to Example 31 above.

[0090]

[0117] The downstream end 842 of the sacrificial cavity 840 is closed, reducing or eliminating the need to capture and dispose of the source material 750 expelled during the MIM process.

[0091]

[0118] 1B in general, and with particular reference to, e.g., Figures 7, 8A, 8B, 8E, and 8F, downstream end 842 of sacrificial cavity 840 is open. The above subject matter of this paragraph characterizes Example 33 of the present disclosure, which also includes subject matter according to Example 31 above.

[0092]

[0119] Having the downstream end 842 of the sacrificial cavity 840 open facilitates inspection and assessment of the quality of the feedstock material 750 discharged during the MIM process so that an estimate can be made of the quality of the feedstock material 750 currently filling the mold cavity 808. Having the downstream end 842 of the sacrificial cavity 840 open also allows for an unlimited amount of feedstock material 750 to be discharged during the MIM process until a selected quality threshold is reached.

[0093]

[0120] 1B in general, and in particular, for example, in FIGS. 7, 8A, 8B, 8E, and 8F, the injector 701 includes a barrel 702 configured to receive the feedstock 750. The injector 701 also includes a press 703 operable to push the feedstock 750 from the barrel 702 through the injection port 802 of the mold 800 into the first gripper cavity 810. The press 703 is further operable to push the feedstock 750 from the first gripper cavity 810 through the middle cavity 814 and the runner cavity 830 in parallel into the second gripper cavity 812. The above-mentioned subject matter of this paragraph characterizes Example 34 of the present disclosure, which also includes subject matter according to any one of Examples 21 to 33 above.

[0094]

[0121] Barrel 702 and press 703 cooperate to controllably pressure feed raw material 750 into mold cavity 808. For example, barrel 702 is in fluid communication with hopper 718. Raw material 750 is gravity fed into hopper 718 and flows into barrel 702. After barrel 702 has been properly initially filled with raw material 750, press 703 is opened to eject raw material 750 into mold cavity 808.

[0095]

[0122] 1B in general, and for example in particular, FIG. 7, press 703 includes a cylinder 710 that is selectively fillable with pressurized fluid 708. Press 703 also includes a piston head 706 located within cylinder 710 and moving toward barrel 702 in response to receipt of pressurized fluid 708 within cylinder 710. Press 703 further includes a piston rod 704 extending from piston head 706 of cylinder 710 into barrel 702 and shaped to push feedstock 750 from barrel 702 through injection port 802 in response to movement of piston head 706 toward barrel 702. The above subject matter of this paragraph characterizes Example 35 of the present disclosure, which also includes subject matter according to Example 34 above.

[0096]

[0123] The piston head 706 , piston rod 704 and cylinder 710 cooperate to provide a hydraulically controllable pressure mechanism for mounting the press 703 .

[0097]

[0124] 1B in general, and, for example, in particular, with reference to FIG. 7, the MIM apparatus 700 further includes a feedstock heater 721 operable to heat the feedstock 750 within the barrel 702. The above subject matter of this paragraph characterizes Example 36 of the present disclosure, which also includes subject matter according to Examples 34 or 35 above.

[0098]

[0125] The feedstock heater 721 facilitates heating the feedstock 750 to a temperature range that is high enough to allow the feedstock 750 to properly flow through the mold cavity 808, but not high enough to melt the binder 749 from the feedstock 750, and not high enough to cross-link and solidify the binder 749 prior to proper filling of the mold cavity 808.

[0099]

[0126] 1B in general, and, for example, in particular, with reference to FIG. 7, feedstock heater 721 includes a resistive heater 720 coupled to barrel 702. The above subject matter of this paragraph characterizes Example 37 of the present disclosure, which also includes subject matter according to Example 36 above.

[0100]

[0127] A resistive heater 720 coupled to the barrel 702 provides an electrically controllable heater mechanism for implementing the feedstock heater 721 .

[0101]

[0128] 1B in general, and for example, in particular, with reference to FIG. 7, the MIM apparatus 700 further includes a barrel 702 configured to receive feedstock 750. The MIM apparatus 700 also includes a screw 711 operable to advance the feedstock 750 through the barrel 702 toward a mold 800 and compress the feedstock 750 adjacent to the mold 800. The above subject matter of this paragraph characterizes Example 38 of the present disclosure, which also includes subject matter according to any one of Examples 21 through 37 above.

[0102]

[0129] The barrel 702 and screw 711 cooperate to provide an effective mechanism for compressing raw material 750 received within the barrel 702 , for example, from a hopper 718 adjacent to the mold 800 .

[0103]

[0130] 1B in general, and for example, in particular, FIG. 7, an injector 701 includes a piston rod 704 extending into a barrel 702 and shaped to push raw material 750 from the barrel 702 through an injection port 802 in a mold 800. A screw 711 includes threads 712 located on an exterior surface of the piston rod 704. The screw 711 also includes a motor 714 operable to rotate the piston rod 704. The above subject matter of this paragraph characterizes Example 39 of the present disclosure, which also includes subject matter according to Example 38 above.

[0104]

[0131] Threads 712 on the exterior surface of piston rod 704 provide a spatially compact and efficient mechanism for mounting screw 711, which is rotatable by motor 714 and shaped to push raw material 750 from barrel 702 into mold 800. For example, motor 714 is operable to selectively rotationally drive piston rod 704 through cooperating gear 716 secured to piston rod 704. In some embodiments, piston rod 704 is further selectively linearly drivable by hydraulic action on piston head 706 positioned within cylinder 710, as described above, further enhancing spatial compactness and efficiency.

[0105]

[0132] In another example, the screw 711 is mounted independently of the piston rod 704 .

[0106]

[0133] 1B generally, and, for example, with particular reference to FIG. 7, MIM apparatus 700 further includes mold heater 791 operable to heat mold 800. The above subject matter of this paragraph characterizes Example 40 of the present disclosure, which also includes subject matter according to any one of Examples 21 through 39 above.

[0107]

[0134] Mold heater 791 facilitates maintaining feedstock 750 within a temperature range during injection that is high enough to allow feedstock 750 to properly flow through mold cavity 808, but not high enough to melt binder 749 from feedstock 750 and not high enough to cross-link and solidify binder 749 prior to proper filling of mold cavity 808. For example, mold heater 791 is operable to maintain feedstock 750 at approximately the same temperature initially induced by feedstock heater 721 during injection while feedstock 750 is within barrel 702.

[0108]

[0135] 1B in general, and, for example, in particular with reference to FIGS. 7, 8A, 8B, 8E, and 8F, mold heater 791 includes at least one channel 890 defined in mold 800. Mold heater 791 also includes at least one heat exchanger 790 operable to heat fluid 792 circulating through at least one channel 890. The above subject matter of this paragraph characterizes Example 41 of the present disclosure, which also includes subject matter according to Example 40 above.

[0109]

[0136] At least one heat exchanger 790 operable to heat a fluid 792 circulating through the at least one channel 890 provides a controllable heating mechanism for implementing the mold heater 791. For example, the at least one channel 890 is implemented as multiple channels, with a respective one of the at least one channel 890 extending through each of the mold sections 860, facilitating consistent heating between the mold sections 860.

[0110]

[0137] 1B in general, and, for example, in particular, with reference to FIG. 7, MIM apparatus 700 further includes a mold cooler 793 operable to cool mold 800. The above subject matter of this paragraph characterizes Example 42 of the present disclosure, which also includes subject matter according to any one of Examples 21 to 41 above.

[0111]

[0138] After injection of the feedstock 750 is complete, the mold cooler 793 facilitates cooling of the feedstock 750 within the mold cavity 808 and thus removal of the integral precursor testing coupons 100 from the mold cavity 808. For example, cooling of the feedstock 750 facilitates handling of the integral precursor testing coupons 100 after formation within the mold 800 and also tends to shrink the integral precursor testing coupons 100, which facilitates separation of the integral precursor testing coupons 100 from the mold cavity walls 866.

[0112]

[0139] 1B in general, and, for example, in particular, in FIGS. 7, 8A, 8B, 8E, and 8F, mold cooler 793 includes at least one channel 890 defined in mold 800. Mold cooler 793 also includes at least one heat exchanger 790 operable to cool fluid 792 circulating through at least one channel 890. The above subject matter of this paragraph characterizes Example 43 of the present disclosure, which also includes subject matter according to Example 42 above.

[0113]

[0140] At least one heat exchanger 790 operable to cool the fluid 792 circulating through the at least one channel 890 provides a controllable cooling mechanism for implementing the mold cooler 793. For example, the at least one channel 890 is implemented as a plurality of channels, with a respective one of the at least one channel 890 extending through each of the mold sections 860, facilitating consistent cooling between the mold sections 860. In some implementations, the heat exchanger 790 is also operable to heat the fluid 792 circulating through the at least one channel 890, as described above, allowing the same one of the heat exchanger 790 and the at least one channel 890 to both heat and cool the mold 800, increasing the spatial compactness and effectiveness of the MIM apparatus 700.

[0114]

[0141] 1B in general, and in particular, for example, in FIGS. 8A, 8B, 8E, and 8F, a first gripping portion cavity 810, a middle portion cavity 814, and a second gripping portion cavity 812 are arranged in series along a longitudinal mold cavity axis 806. The middle portion cavity 814 includes a gauge portion cavity 820 that defines a gauge cross-sectional flow range perpendicular to the longitudinal mold cavity axis 806. The gauge cross-sectional flow range is the minimum of a set of values ​​of the cross-sectional flow range perpendicular to the longitudinal mold cavity axis 806 at all locations along the first gripping portion cavity 810, the middle portion cavity 814, and the second gripping portion cavity 812. The above subject matter of this paragraph characterizes Example 44 of the present disclosure, which also includes subject matter according to any one of Examples 21 to 43 above.

[0115]

[0142] The gauge section 120 of the integral precursor test coupon 100 (shown in FIG. 1 ) is created as the expected failure location of the test coupon 900 (shown in FIG. 9 ) during material property testing, with the gauge section flow area being the minimum of a set of values ​​of cross-sectional flow area at all locations along the first gripping portion cavity 810, the middle portion cavity 814, and the second gripping portion cavity 812. The cross section of the gauge section 120 can be used along with applied force measurements from standard off-the-shelf material property testing equipment (e.g., a tensile testing machine, not shown) to calculate the material properties of the material of the test coupon 900.

[0116]

[0143] 1C in general, and for example, to FIGS. 10A-10E in particular, a flash removal tool 1000 is disclosed. The flash removal tool 1000 includes a tool body 1002 extending along a longitudinal tool axis 1004. The flash removal tool 1000 also includes teeth 1010 projecting in a first direction 1090 from the tool body 1002. The flash removal tool 1000 further includes an engagement surface 1020 located a preselected distance 1022 from the teeth 1010 along the longitudinal tool axis 1004 and perpendicular to the longitudinal tool axis 1004. The teeth 1010 include a shear surface 1014 facing in the first direction 1090 and located an offset distance 1012 away from the longitudinal tool axis 1004 in a second direction 1092. The first direction 1090 and the second direction 1092 are mutually orthogonal and define a plane perpendicular to the longitudinal tool axis 1004. The above subject matter of this paragraph characterizes Example 45 of the present disclosure.

[0117]

[0144] The engagement surface 1020 is located a preselected distance 1022 away from the tines 1010, allowing the tines 1010 to longitudinally align with the gauge portion 120 when the engagement surface 1020 engages the integral precursor test coupon 100 (shown in FIG. 1 ). Additionally, the tines 1010 protrude from the tool body 1002 in a first direction 1090 and have shear surfaces 1014 located an offset distance 1012 away from the longitudinal tool axis 1004 in a second direction 1092, allowing the tines 1010 to slide between the runners 130 (shown in FIG. 1 ) of the integral precursor test coupon 100, allowing the shear surfaces 1014 to precisely align with the flash 180 on the gauge portion 120. Thus, the flash removal tool 1000 facilitates removal of the flash 180 from the gauge portion 120 while the runner 130 remains attached to the integral precursor test coupon 100 without the need for complex alignment or adjustment.

[0118]

[0145] 1C in general, and Figures 10A-10E in particular, for example, an engagement surface 1020 is defined on the tool body 1002, and the preselected distance 1022 is not adjustable. The above subject matter of this paragraph characterizes Example 46 of the present disclosure, which also includes subject matter according to Example 45 above.

[0119]

[0146] The preselected distance 1022 is not adjustable, simplifying manufacture and facilitating use of the flash removal tool 1000. For example, the integral precursor test coupon 100 is manufactured such that the first precursor coupon end 102 is separated from the gauge portion 120 (shown in FIG. 1 ) by a standard longitudinal distance, and the flash removal tool 1000 is manufactured to have a preselected distance 1022 that is not adjustable and is equal to the standard longitudinal distance from the first precursor coupon end 102 to the gauge portion 120.

[0120]

[0147] 1C in general, and, for example, with reference to Figures 10A and 10C in particular, the flash removal tool 1000 further includes an extendable portion 1041 that can move relative to the tool body 1002 to adjust the preselected distance 1022. The above subject matter in this paragraph characterizes Example 47 of the present disclosure, which also includes subject matter according to Examples 45 or 46 above.

[0121]

[0148] The adjustability of the preselected distance 1022 via the extendable portion 1041 that is moveable relative to the tool body 1002 facilitates the adjustability of the flash removal tool 1000 to various sized integral precursor test coupons 100 (shown in FIG. 1 ). For example, the integral precursor test coupons 100 are manufactured in various longitudinal sizes that correspond to the various sizes of test coupons 900 required for use in various material property testers (not shown). The adjustability of the preselected distance 1022 allows a single tool, such as the flash removal tool 1000, to be used with multiple sizes of integral precursor test coupons 100.

[0122]

[0149] 1C in general, and, for example, in particular, with reference to FIGS. 10A and 10C, the extendable portion 1041 includes a telescoping portion 1040 coupled to the tool body 1002. An engagement surface 1020 is defined on the telescoping portion 1040. The above subject matter of this paragraph characterizes Example 48 of the present disclosure, which also includes subject matter according to Example 47 above.

[0123]

[0150] The telescoping portion 1040 coupled to the tool body 1002 provides a mechanically simple and effective structure for mounting the extendable portion 1041 .

[0124]

[0151] 1C generally, and, for example, with reference to Figures 10A and 10C in particular, the flash removal tool 1000 further includes a locking portion 1043 operable to selectively lock the telescoping portion 1040 in place relative to the tool body 1002 after the preselected distance 1022 has been adjusted. The above subject matter of this paragraph characterizes Example 49 of the present disclosure, which also includes subject matter according to Example 48 above.

[0125]

[0152] The locking portion 1043 promotes stability and ease of use of the flash removal tool 1000 having an adjustable preselected distance 1022 .

[0126]

[0153] 1C in general, and for example, in particular, FIG. 10A, the locking portion 1043 includes a detent 1044 located on one of the telescoping portions 1040 or the tool body 1002, and a plurality of catches 1046 longitudinally disposed on another one of the telescoping portions 1040 or the tool body 1002. Each of the catches 1046 is configured to interfere with the detent 1044 when the telescoping portion 1040 is correspondingly adjusted relative to the tool body 1002. The above subject matter of this paragraph characterizes Example 50 of the present disclosure, which also includes subject matter according to Example 49 above.

[0127]

[0154] The detent 1044 and catch 1046 provide a mechanically simple and effective structure for mounting the locking portion 1043 .

[0128]

[0155] 1C generally, and for example, in particular, FIGS. 10A-10C, the flash removal tool 1000 further includes a locating groove 1006 defined in the tool body 1002. The locating groove 1006 extends longitudinally between the engagement surface 1020 and the teeth 1010 and faces in a first direction 1090. The above subject matter of this paragraph characterizes Example 51 of the present disclosure, which also includes subject matter according to any of Examples 45-50 above.

[0129]

[0156] The positioning grooves 1006 facilitate stable positioning of the flash removal tool 1000 relative to the unitary precursor test coupon 100 (shown in FIG. 1).

[0130]

[0157] 1C in general, and, for example, in particular, FIGS. 10A-10C, engagement surface 1020 forms longitudinal end wall 1034 of locating groove 1006. The above subject matter of this paragraph characterizes Example 52 of the present disclosure, which also includes subject matter according to Example 51 above.

[0131]

[0158] The engagement surface 1020 forms the longitudinal end wall 1034 of the positioning groove 1006, thereby combining a mechanism for longitudinal positioning of the tooth portion 1010 with an additional mechanism for stable positioning of the flash removal tool 1000 relative to the integral precursor test coupon 100 (shown in FIG. 1), facilitating a compact design of the flash removal tool 1000.

[0132]

[0159] 1C in general, and, for example, in particular, with reference to Figures 10A-10C, the locating groove 1006 includes a cylindrically contoured portion 1030 that extends parallel to the longitudinal tool axis 1004. The above subject matter in this paragraph characterizes Example 53 of the present disclosure, which also includes subject matter according to Examples 51 or 52 above.

[0133]

[0160] The cylindrically contoured portion 1030 of the positioning groove 1006 facilitates stable positioning of the flash removal tool 1000 relative to the first gripping portion 110 of the integral precursor test coupon 100 (shown in FIG. 1 ) for embodiments in which the first gripping portion 110 has a cylindrical profile complementary to the cylindrically contoured portion 1030.

[0134]

[0161] 1C in general, and, for example, in particular, with reference to Figures 10A-10C, the locating groove 1006 further includes a tapered portion 1032 extending longitudinally between the cylindrically contoured portion 1030 and the teeth 1010 and parallel to the longitudinal tool axis 1004. The above subject matter of this paragraph characterizes Example 54 of the present disclosure, which also includes subject matter according to Example 53 above.

[0135]

[0162] The tapered portion 1032 of the positioning groove 1006 facilitates stable positioning of the flash removal tool 1000 relative to the intermediate portion 114 (shown in FIG. 1 ) of the integral precursor test coupon 100 for embodiments in which the intermediate portion 114 adjacent the first gripping portion 110 has a longitudinally tapered profile complementary to the tapered portion 1032.

[0136]

[0163] 1C in general, and for example, in particular with reference to FIGS. 10A and 10C, the flash removal tool 1000 further includes an auxiliary groove 1035 defined in the tool body 1002. The teeth 1010 divide the tool body 1002 longitudinally into two sides. The locating groove 1006 extends longitudinally through one of the two sides, and the auxiliary groove 1035 extends longitudinally through the other of the two sides and faces in a first direction 1090. The above subject matter of this paragraph characterizes Example 55 of the present disclosure, which also includes subject matter according to any one of Examples 51 to 54 above.

[0137]

[0164] The secondary grooves 1035 further facilitate stable positioning of the flash removal tool 1000 relative to the unitary precursor test coupon 100 (shown in FIG. 1).

[0138]

[0165] 1C in general, and e.g., with reference to Figures 10A and 10C in particular, the auxiliary groove 1035 includes a cylindrically contoured auxiliary portion 1036 that extends parallel to the longitudinal tool axis 1004. The above subject matter of this paragraph characterizes Example 56 of the present disclosure, which also includes subject matter according to Example 55 above.

[0139]

[0166] The cylindrically contoured auxiliary portion 1036 of the auxiliary groove 1035 facilitates stable positioning of the flash removal tool 1000 relative to the second gripping portion 112 of the integral precursor test coupon 100 (shown in FIG. 1 ) for embodiments in which the second gripping portion 112 has a cylindrical profile complementary to the cylindrically contoured auxiliary portion 1036.

[0140]

[0167] 1C in general, and e.g., with reference to Figures 10A and 10C in particular, the auxiliary groove 1035 further includes a tapered auxiliary portion 1038 that is parallel to the longitudinal tool axis 1004 and extends longitudinally between the cylindrically contoured auxiliary portion 1036 and the tooth 1010. The above subject matter of this paragraph characterizes Example 57 of the present disclosure, which also includes subject matter according to Example 56 above.

[0141]

[0168] The tapered auxiliary portion 1038 of the auxiliary groove 1035 facilitates stable positioning of the flash removal tool 1000 relative to the intermediate portion 114 (shown in FIG. 1 ) of the integral precursor test coupon 100 for embodiments in which the intermediate portion 114 adjacent the second gripping portion 112 has a longitudinally tapered profile complementary to the tapered auxiliary portion 1038.

[0142]

[0169] 1C generally, and for example, with particular reference to FIG. 10B, the flash removal tool 1000 further includes a second tines 1011. A longitudinal tool axis 1004 is located between the tines 1010 and the second tines 1011. The above subject matter of this paragraph characterizes Example 58 of the present disclosure, which also includes subject matter according to any one of Examples 45 to 57 above.

[0143]

[0170] A second tooth portion 1011 positioned opposite the tooth portion 1010 facilitates removal of multiple portions of the flash 180 (shown in FIG. 10E) without requiring disengagement of the flash removal tool 1000 from the integral precursor test coupon 100 (shown in FIG. 1) and subsequent repositioning of the flash removal tool 1000 to reposition the tooth portion 1010.

[0144]

[0171] 1C generally, and for example, with particular reference to FIG. 10B, the second tooth 1011 is located a preselected distance 1022 away from the engagement surface 1020 along the longitudinal tool axis 1004. The above subject matter of this paragraph characterizes Example 59 of the present disclosure, which also includes subject matter according to Example 58 above.

[0145]

[0172] By positioning the engagement surface 1020 a preselected distance 1022 away from the second tooth portion 1011, the second tooth portion 1011 can be longitudinally aligned with the gauge portion 120 at the same time that the tooth portion 1010 is longitudinally aligned with the gauge portion 120 when the engagement surface 1020 engages the integral precursor test coupon 100 (shown in FIG. 1).

[0146]

[0173] 1C in general, and for example, in particular with reference to FIG. 10B, the teeth 1010 are integral with the tool body 1002. The above-mentioned subject matter of this paragraph characterizes Example 60 of the present disclosure, which also includes subject matter according to any one of Examples 45 to 59 above.

[0147]

[0174] Having the teeth 1010 integral with the tool body 1002 simplifies manufacturing of the flash removal tool 1000 .

[0148]

[0175] 1C in general, and for example, in particular, FIG. 10A, the teeth 1010 are formed separately from and coupled to the tool body 1002. The above subject matter of this paragraph characterizes Example 61 of the present disclosure, which also includes subject matter according to any one of Examples 45 to 59 above.

[0149]

[0176] By forming the teeth 1010 separately from the tool body 1002 and connecting it to the tool body 1002, it becomes easier to manufacture flash removal tools 1000 having a variety of longitudinal sizes from standard elements used to form the tool body 1002 and the teeth 1010.

[0150]

[0177] 1C in general, and for example, in particular with reference to FIGS. 10A and 10B, a tool body 1002 extends along a longitudinal tool axis 1004 from a first end 1050 to a second end 1052. An engagement surface 1020 is located adjacent the first end 1050. The above subject matter of this paragraph characterizes Example 62 of the present disclosure, which also includes subject matter according to any one of Examples 45 to 61 above.

[0151]

[0178] The location of the engagement surface 1020 adjacent the first end 1050 of the flash removal tool 1000 facilitates a compact design of the flash removal tool 1000.

[0152]

[0179] 1C in general, and, for example, in particular, with reference to Figures 10A and 10B, the tooth 1010 is located at the second end 1052. The above subject matter of this paragraph characterizes Example 63 of the present disclosure, which also includes subject matter according to Example 62 above.

[0153]

[0180] The location of the teeth 1010 at the second end 1052 of the flash removal tool 1000 facilitates a compact design of the flash removal tool 1000.

[0154]

[0181] 1C in general, and with particular reference to, for example, Figures 10A and 10B, the teeth 1010 are spaced apart from the second end 1052 along the longitudinal tool axis 1004. The above subject matter of this paragraph characterizes Example 64 of the present disclosure, which also includes subject matter according to Example 62 above.

[0155]

[0182] The teeth 1010 are longitudinally spaced from the second end 1052 of the flash removal tool 1000 to facilitate stable coupling of the flash removal tool 1000 to the unitary precursor test coupon 100 (shown in FIG. 1 ). For example, a secondary groove 1035 is included in the longitudinal portion of the tool body 1002 between the teeth 1010 and the second end 1052.

[0156]

[0183] 11A-11C generally, and for example, to Figures 2A-2C, 8A-8F, and 9 in particular, a method 1100 of making test coupons 900 using a mold 800 is disclosed. Mold 800 defines a mold cavity 808 including a first gripping portion cavity 810, a second gripping portion cavity 812, and a middle portion cavity 814 interconnecting first gripping portion cavity 810 and second gripping portion cavity 812. Mold cavity 808 further includes a runner cavity 830 that directly interconnects first gripping portion cavity 810 and second gripping portion cavity 812, and is not directly connected to middle portion cavity 814. The method 1100 includes injecting a feedstock 750 including a metal powder 748 into the mold cavity 808 to form a one-piece precursor testing coupon 100 within the mold cavity 808 (block 1118). The one-piece precursor testing coupon 100 includes a first gripping portion 110 having a shape complementary to a shape of the first gripping portion cavity 810, and a second gripping portion 112 having a shape complementary to a shape of the second gripping portion cavity 812. The one-piece precursor testing coupon 100 also includes a middle portion 114 having a shape complementary to a shape of the middle portion cavity 814, and runners 130 each having a shape complementary to a shape of a corresponding one of the runner cavities 830. The method 1100 also includes removing the runners 130 from the one-piece precursor testing coupon 100 (block 1142). The above subject matter of this paragraph characterizes Example 65 of the present disclosure.

[0157]

[0184] The method 1100 allows for uniform distribution of the feedstock material 750 within the first gripping portion cavity 810, the middle portion cavity 814, and the second gripping portion cavity 812, reducing or eliminating voids, and further reducing or eliminating shearing of the binder 749 contained within the feedstock material 750 along with the metal powder 748, facilitating the formation of the unitary precursor test coupon 100 in the mold 800. More specifically, the runner cavity 830 allows a portion of the feedstock material 750 to bypass the flow restriction caused by the middle portion cavity 814 and backfill the downstream portion of the unitary precursor test coupon 100 (shown in FIG. 1A ). Thus, the bypass flow range provided by the runner cavity 830 allows the formation of the unitary precursor test coupon 100 with proper distribution and integrity of the feedstock material 750 at injection speeds that avoid issues of binder shearing or premature binder cross-linking. Removal of the runner 130 from the unitary precursor test coupon 100 leaves the first clamped portion 110, the middle portion 114, and the second clamped portion 112 of the test coupon 900 for material property testing, such as in a tensile testing machine (not shown).

[0158]

[0185] 11A-11C in general, and in particular, for example, in FIGS. 7, 8A, 8B, 8E, and 8F, according to method 1100, injecting feedstock 750 into mold cavity 808 (block 1118) includes pressurizing feedstock 750 in barrel 702 (block 1120). Feedstock 750 is extruded from barrel 702 through injection port 802 of mold 800 into first gripper cavity 810, and then extruded from first gripper cavity 810 through middle cavity 814 and runner cavity 830 in parallel into second gripper cavity 812. The above-mentioned subject matter of this paragraph characterizes Example 66 of the present disclosure, which also includes subject matter according to Example 65 above.

[0159]

[0186] The barrel 702 provides a suitable feed structure to pressurize the feedstock 750 and cause it to be injected into the mold cavity 808. For example, the barrel 702 is in fluid communication with a hopper 718. The feedstock 750 is gravity fed into the hopper 718 and flows into the barrel 702. After a suitable initial filling of the barrel 702 with the feedstock 750, the feedstock 750 is pressurized causing it to be injected into the mold cavity 808. The runner cavity 830 provides a flow path for the feedstock 750 to be injected parallel to the middle portion cavity 814 to facilitate backfilling of the downstream portion of the unitary precursor test coupon 100 (shown in FIG. 1A ).

[0160]

[0187] 11A-11C generally, and for example, with particular reference to FIG. 7, according to method 1100, pressurizing raw material 750 in barrel 702 (block 1120) includes applying hydraulic pressure to raw material 750 (block 1122). The above-mentioned subject matter in this paragraph characterizes Example 67 of the present disclosure, which also includes subject matter according to Example 66 above.

[0161]

[0188] The application of hydraulic pressure provides a suitable controllable pressurizing mechanism for ejecting the raw material 750. For example, a piston head 706 is located within a cylinder 710 and is movable toward the barrel 702 in response to receipt of a pressurized fluid 708 (e.g., hydraulic fluid or water) within the cylinder 710. A piston rod 704 extending from the piston head 706 of the cylinder 710 into the barrel 702 is shaped to push the raw material 750 out of the barrel 702 and through an ejection port 802 in response to hydraulically pressurized movement of the piston head 706 toward the barrel 702.

[0162]

[0189] 11A-11C in general, and for example, with particular reference to FIG. 7, method 1100 further includes heating feedstock material 750 (block 1104) prior to injecting feedstock material 750 (block 1118) into mold cavity 808. The above subject matter in this paragraph characterizes Example 68 of the present disclosure, which also includes subject matter according to Examples 66 or 67 above.

[0163]

[0190] Heating the raw material 750 prior to injecting it into the mold cavity 808 facilitates having the raw material 750 within a temperature range that is high enough to allow the raw material 750 to flow properly through the mold cavity 808, but not high enough to melt the binder 749 from the raw material 750, and not high enough to crosslink and solidify the binder 749 prior to proper filling of the mold cavity 808.

[0164]

[0191] 11A-11C in general, and for example, in particular, FIG. 7, the method 1100 further includes receiving a feedstock 750 in a barrel 702 (block 1102). The method 1100 also includes advancing the feedstock 750 through the barrel 702 toward a mold 800 (block 1106) prior to injecting the feedstock 750 into a mold cavity 808 (block 1118). The feedstock 750 is compressed adjacent to the mold 800. The above subject matter of this paragraph characterizes Example 69 of the present disclosure, which also includes subject matter according to any one of Examples 65 through 68 above.

[0165]

[0192] Advancing the feedstock 750 through the barrel 702 and compressing the feedstock 750 adjacent to the mold 800 reduces air pockets within the feedstock 750 and increases the uniformity of the feedstock 750 prior to injecting the feedstock 750 into the mold cavity 808. For example, a screw 711 positioned within the barrel 702 advances the feedstock 750 received from the hopper 718 toward the mold 800 and compresses the feedstock 750 adjacent to the mold 800.

[0166]

[0193] 11A-11C in general, and for example, with particular reference to FIG. 7, method 1100 further includes heating mold 800 (block 1108) prior to injecting feedstock material 750 (block 1118) into mold cavity 808. The above subject matter of this paragraph characterizes Example 70 of the present disclosure, which also includes subject matter according to any one of Examples 65 to 69 above.

[0167]

[0194] Heating the mold 800 facilitates maintaining the feedstock 750 within a temperature range during injection that is high enough to allow the feedstock 750 to properly flow through the mold cavity 808, but not high enough to melt the binder 749 from the feedstock 750 and not high enough to crosslink and solidify the binder 749 prior to proper filling of the mold cavity 808. For example, the mold 800 is heated to a temperature that maintains the feedstock 750 during injection at approximately the same temperature that was originally induced by heating the feedstock 750 in the barrel 702.

[0168]

[0195] 11A-11C in general, and e.g., in particular, e.g., e.g., e.g. 7, 8A, 8B, 8E, and 8F, according to method 1100, heating mold 800 (block 1108) includes circulating fluid 792 (block 1110) through at least one heat exchanger 790 and at least one channel 890 defined in mold 800. The above subject matter of this paragraph characterizes Example 71 of the present disclosure, which also includes subject matter according to Example 70 above.

[0169]

[0196] Circulating the fluid 792 through the heat exchanger 790 and the at least one channel 890 defined in the mold 800 provides a controllable heating mechanism for heating the mold 800. For example, the at least one channel 890 is implemented as multiple channels, with each one of the at least one channel 890 extending through each of the mold sections 860, facilitating consistent heating between the mold sections 860.

[0170]

[0197] 11A-11C in general, and for example, with particular reference to FIG. 7, the method 1100 further includes cooling the mold 800 (block 1112) after injecting the feedstock material 750 into the mold cavity 808 (block 1118). The above subject matter of this paragraph characterizes Example 72 of the present disclosure, which also includes subject matter according to any one of Examples 65 to 71 above.

[0171]

[0198] Cooling the mold 800 after injection of the feedstock 750 is complete facilitates cooling of the feedstock 750 within the mold cavity 808 and thus removal of the integral precursor testing coupons 100 from the mold cavity 808. For example, cooling of the feedstock 750 facilitates handling of the integral precursor testing coupons 100 after formation within the mold 800 and also tends to shrink the integral precursor testing coupons 100, which facilitates separation of the integral precursor testing coupons 100 from the mold cavity walls 866.

[0172]

[0199] 11A-11C in general, and e.g., in particular, e.g., e.g., e.g. 7, 8A, 8B, 8E, and 8F, according to method 1100, cooling mold 800 (block 1112) includes circulating fluid 792 (block 1114) through at least one heat exchanger 790 and at least one channel 890 defined in mold 800. The above subject matter of this paragraph characterizes Example 73 of the present disclosure, which also includes subject matter according to Example 72 above.

[0173]

[0200] Circulating fluid 792 through heat exchanger 790 and at least one channel 890 defined in mold 800 provides a controllable cooling mechanism for cooling mold 800. For example, the at least one channel 890 is implemented as a plurality of channels, with each one of the at least one channel 890 extending through each of the mold sections 860, facilitating consistent cooling between mold sections 860.

[0174]

[0201] 11A-11C in general, and for example, in particular, FIG. 7, 8A, 8B, 8E, and 8F, according to method 1100, injecting feedstock material 750 into mold cavity 808 (block 1118) includes extruding a portion of feedstock material 750 from mold cavity 808 into sacrificial cavity 840 in downstream fluid communication with mold cavity 808 (block 1126). The above subject matter of this paragraph characterizes Example 74 of the present disclosure, which also includes subject matter according to any one of Examples 65 to 73 above.

[0175]

[0202] Extruding a portion of the feedstock 750 from the mold cavity 808 into the sacrificial cavity 840 allows impurities and / or air initially present in the mold cavity 808 and / or feedstock 750 to be evacuated from the mold cavity 808 at a downstream location as additional amounts of feedstock 750 continue to be injected into the mold cavity 808 at an upstream location. For example, the feedstock 750 may initially be at a temperature that causes the binder 749 to partially melt from the feedstock 750 (which would undesirably alter the material properties of the unitary precursor test coupon 100). An initial portion of the feedstock 750 may be extruded through the mold cavity 808 into the sacrificial cavity 840 as the temperature of the feedstock 750 is adjusted to fill the mold cavity 808 with feedstock 750 having reduced or eliminated melting of the binder 749. In some examples, the sacrificial cavity 840 has an open downstream end 842 and the raw material 750 flowing through the downstream end 842 is observed to determine, for example, whether adjustments are needed to the temperature of the raw material 750 in the barrel 702 and / or other parameters affecting the quality of the raw material 750.

[0176]

[0203] 11A-11C in general, and with particular reference to, for example, FIGS. 7 and 8A-8F, the method 1100 further includes, after injecting the feedstock material 750 into the mold cavity 808 (block 1118), separating mold sections 860 of the mold 800 along at least one of the parting surfaces 870 (block 1130), and extending ejector pins 850 from at least one of the mold sections 860 into the mold cavity 808 (block 1132) such that the integral precursor test coupon 100 separates from the mold 800. The above subject matter of this paragraph characterizes Example 75 of the present disclosure, which also includes subject matter according to any one of Examples 65 to 74 above.

[0177]

[0204] Extending the ejector pins 850 into the mold cavity 808 facilitates separation of the integral precursor testing coupon 100 from the mold section 860 after the mold sections 860 are disassembled to remove the integral precursor testing coupon 100. More specifically, extending the ejector pins 850 into the mold cavity 808 pushes the integral precursor testing coupon 100 away from the mold cavity walls 866.

[0178]

[0205] 11A-11C in general, and for example, with particular reference to FIG. 8D , the method 1100 further includes positioning the ejector pin 850 in a retracted position (block 1116) prior to injecting the feedstock material 750 into the mold cavity 808 (block 1118), such that during the injection of the feedstock material 750 into the mold cavity 808 (block 1118), the tapered lower surface 854 of the pin head 852 of the ejector pin 850 is in direct sealing contact with the tapered portion 864 of the pin chamber 862 in which the ejector pin 850 is sealed. The above-mentioned subject matter of this paragraph characterizes Example 76 of the present disclosure, which also includes subject matter according to Example 75 above.

[0179]

[0206] The tapered lower surface 854 of the pin head 852 is in direct sealing contact with the tapered portion 864 of the pin chamber 862, facilitating the formation of a positive seal between the pin head 852 and the mold cavity wall 866 during injection of the feedstock 750. More specifically, when the ejector pin 850 is in the retracted position, the positive pressure within the mold cavity 808 acts against the pin head 852, tending to press the ejector pin 850 deeper into the pin chamber 862, such that the greater the pressure within the mold cavity 808, the better the seal formed between the tapered lower surface 854 and the tapered portion 864 of the pin chamber 862. Thus, the tapered portion 864 of the pin chamber 862 tends to reduce or eliminate the possibility of the ejector pin 850 becoming stuck in the retracted position due to the bonding agent 749 penetrating between the pin head 852 and the mold cavity wall 866, thereby making it impossible to eject the integral precursor test coupon 100.

[0180]

[0207] 11A-11C in general, and particularly, for example, in FIGS. 2A-2C and 7, feedstock material 750 further includes bonding agent 749, and according to method 1100, injecting feedstock material 750 into mold cavity 808 (block 1118) includes forming a one-piece precursor test coupon 100 in a green state (block 1128). Method 1100 further includes debonding one-piece precursor test coupon 100 from the green state to a brown state (block 1138). The above subject matter of this paragraph characterizes Example 77 of the present disclosure, which also includes subject matter according to any one of Examples 65 to 76 above.

[0181]

[0208] Debonding the monolithic precursor test coupon 100 from the green state to the brown state facilitates the ultimate fabrication of a test coupon 900 (shown in FIG. 9 ) having desired material properties. For example, the monolithic precursor test coupon 100 may be subjected to an appropriate thermal or solvent-based process to remove the bonding agent 749.

[0182]

[0209] 11A-11C in general, and, for example, with reference to Figures 2A-2C and 9 in particular, according to method 1100, removing runner 130 (block 1142) is performed prior to decoupling integral precursor test coupon 100 from the green state to the brown state (block 1138). The above subject matter of this paragraph characterizes Example 78 of the present disclosure, which also includes subject matter according to Example 77 above.

[0183]

[0210] Removing the runners 130 prior to debonding simplifies removal of the runners 130 from the integral precursor test coupons 100 due to the lack of structural strength of the integral precursor test coupons 100 in the green state compared to the final material state.

[0184]

[0211] 11A-11C, and in particular, for example, with reference to Figures 2A-2C and 9, according to method 1100, removing runner 130 (block 1142) is performed after debonding unitary precursor test coupon 100 from the green state to the brown state (block 1138). The above subject matter of this paragraph characterizes Example 79 of the present disclosure, which also includes subject matter according to Example 77 above.

[0185]

[0212] Removing the runners 130 after debonding facilitates maintaining the structural integrity of the one-piece precursor test coupon 100 during the debonding process. More specifically, the runners 130 interconnect the first gripping portion 110 and the second gripping portion 112, thereby increasing the structural stability of the first gripping portion 110, the second gripping portion 112, and the middle portion 114, thereby preventing breakage or warping of the first gripping portion 110, the second gripping portion 112, and the middle portion 114 during and after debonding.

[0186]

[0213] 11A-11C, and in particular, for example, with reference to FIGS. 2A-2C and 9, method 1100 further includes sintering unitary precursor test coupon 100 from the brown state to a final material state (block 1140). The above subject matter of this paragraph characterizes Example 80 of the present disclosure, which also includes subject matter according to any one of Examples 77 to 79 above.

[0187]

[0214] Sintering the monolithic precursor test coupon 100 from the brown state to the final material state facilitates fabrication of a test coupon 900 (shown in FIG. 9 ) having desired material properties. For example, the monolithic precursor test coupon 100 is exposed to temperatures in excess of 1100 degrees Celsius (2012 degrees Fahrenheit) in a suitable vacuum or other non-oxidizing atmosphere. In the final material state, the metal powder 748 originally contained in the source material 750 and held within the substance 150 has been transformed into the sintered metal 950.

[0188]

[0215] 11A-11C, and in particular, for example, with reference to Figures 2A-2C and 9, according to method 1100, removing runner 130 (block 1142) is performed prior to sintering unitary precursor test coupon 100 from the brown state to the final material state (block 1140). The above subject matter of this paragraph characterizes Example 81 of the present disclosure, which also includes subject matter according to Example 80 above.

[0189]

[0216] Removing the runners 130 prior to sintering simplifies removal of the runners 130 from the integral precursor test coupons 100 due to the lack of structural strength of the integral precursor test coupons 100 in the brown state compared to the final material state.

[0190]

[0217] 11A-11C in general, and, for example, with reference to Figures 2A-2C and 9 in particular, according to method 1100, removing runner 130 (block 1142) is performed after sintering unitary precursor test coupon 100 from the brown state to the final material state (block 1140). The above subject matter of this paragraph characterizes Example 82 of the present disclosure, which also includes subject matter according to Example 80 above.

[0191]

[0218] Removing the runners 130 after sintering facilitates maintaining the structural integrity of the unitary precursor test coupon 100 during the sintering process. More specifically, the runners 130 interconnect the first gripping portion 110 and the second gripping portion 112, thereby increasing the structural stability of the first gripping portion 110, the second gripping portion 112, and the middle portion 114, thereby preventing breakage or warping of the first gripping portion 110, the second gripping portion 112, and the middle portion 114 during and after sintering (e.g., during a post-sintering cool down process).

[0192]

[0219] 11A-11C generally, and for example, with reference to FIGS. 7, 8A, 8B, 8E, and 8F in particular, a first gripping portion cavity 810, a middle portion cavity 814, and a second gripping portion cavity 812 are disposed in series along a longitudinal mold cavity axis 806. The middle portion cavity 814 includes a gauge portion cavity 820 that defines a gauge cross-sectional flow range perpendicular to the longitudinal mold cavity axis 806. The gauge cross-sectional flow range is the minimum of a set of cross-sectional flow ranges perpendicular to the longitudinal mold cavity axis 806 at all locations along the first gripping portion cavity 810, the middle portion cavity 814, and the second gripping portion cavity 812. According to the method 1100, injecting the raw material 750 into the mold cavity 808 (block 1118) includes simultaneously flowing the raw material 750 from the first gripper cavity 810 through the middle cavity 814 into the second gripper cavity 812 through a first flow path, and from the first gripper cavity 810 through the runner cavity 830 into the second gripper cavity 812 through a second flow path arranged parallel to each other with respect to the first flow path (block 1124). The above-mentioned subject matter of this paragraph characterizes Example 83 of the present disclosure, which also includes subject matter according to any one of Examples 65 to 82 above.

[0193]

[0220] The runner cavity 830 allows a portion of the feedstock material 750 to bypass the flow restriction caused by the gauge cross-sectional flow area being the minimum of a set of cross-sectional flow areas perpendicular to the longitudinal mold cavity axis 806. More specifically, the gauge portion cavity 820 and the multiple second flow paths parallel to the first flow paths through each other provide backfilling of the downstream portion of the unitary precursor test coupon 100 (shown in FIG. 1A ). The bypass flow area provided by the runner cavity 830 thus enables the formation of a unitary precursor test coupon 100 with proper distribution and integrity of the feedstock material 750 at injection speeds that avoid issues of binder shear or premature binder cross-linking.

[0194]

[0221] 12A-12D generally, and for example, FIGs. 10A-10E in particular, a method 1200 of removing flash 180 from a gauge portion 120 of a unitary precursor test coupon 100 using a flash removal tool 1000 is disclosed. The flash removal tool 1000 includes a tool body 1002 extending along a longitudinal tool axis 1004. The flash removal tool 1000 also includes teeth 1010 and an engagement surface 1020 spaced from the teeth 1010 along the longitudinal tool axis 1004. The teeth 1010 include a shear surface 1014 that projects in a first direction 1090 from the tool body 1002 and faces in the first direction 1090 and is located at an offset distance 1012 away from the longitudinal tool axis 1004 in a second direction 1092. The first direction 1090 and the second direction 1092 are orthogonal to one another and define a plane perpendicular to the longitudinal tool axis 1004. The method 1200 includes coupling an engagement surface 1020 of the flash removal tool 1000 to the first precursor coupon end 102 of the integral precursor test coupon 100 (block 1210). The method 1200 also includes orienting the longitudinal tool axis 1004 parallel to the longitudinal axis of symmetry 106 of the integral precursor test coupon 100 (block 1214). The shear plane 1014 is longitudinally coincident with the flash 180. The method 1200 further includes shearing the flash 180 from the gauge portion 120 using the shear plane 1014 (block 1236). The above subject matter of this paragraph characterizes Example 84 of the present disclosure.

[0195]

[0222] The teeth 1010 project from the tool body 1002 in a first direction 1090 and have shear surfaces 1014 located an offset distance 1012 away from the longitudinal tool axis 1004 in a second direction 1092 such that when the engagement surface 1020 of the flash removal tool 1000 is coupled to the first precursor coupon end 102 and the longitudinal tool axis 1004 is oriented parallel to the longitudinal axis of symmetry 106 of the unitary precursor test coupon 100, the shear surfaces 1014 are aligned longitudinally with the flash 180 to facilitate removal of the flash 180 from the gauge portion 120 at increased speeds without the need for complex alignment procedures or adjustments. For example, as shown in FIG. 10E , the gauge portion 120 has a circular cross-section and a radius 118, with the offset distance 1012 being equal to the radius 118 plus a tolerance 1016.

[0196]

[0223] 12A-12D in general, and for example, in particular, with reference to FIG. 10E, according to method 1200, orienting the longitudinal tool axis 1004 parallel to the longitudinal axis of symmetry 106 of the integral precursor test coupon 100 (block 1214) includes positioning the shear plane 1014 at a radial distance 119 from the longitudinal axis of symmetry 106 (block 1216). A flash 180 protrudes radially through the radial distance 119 from the surface 116 of the gauge portion 120. The above-mentioned subject matter of this paragraph characterizes Example 85 of the present disclosure, which also includes subject matter according to Example 84 above.

[0197]

[0224] By positioning the shear surface 1014 at a radial distance 119 from the longitudinal axis of symmetry 106, the shear surface 1014 can be aligned with the flash 180 protruding from the surface 116 without requiring any complex alignment procedures or adjustments beyond those required for connecting the engagement surface 1020 to the integral precursor test coupon 100, as well as the orientation of the longitudinal tool axis 1004 parallel to the longitudinal axis of symmetry 106 of the integral precursor test coupon 100.

[0198]

[0225] 12A-12D in general, and in particular, for example, in FIGS. 10C and 10D, the one-piece precursor test coupon 100 further includes a first gripping portion 110, a second gripping portion 112, and a middle portion 114 interconnecting the first gripping portion 110 and the second gripping portion 112. The one-piece precursor test coupon 100 also includes a runner 130 that directly interconnects the first gripping portion 110 and the second gripping portion 112 and is not directly connected to the middle portion 114. The middle portion 114 of the one-piece precursor test coupon 100 includes a gauge portion 120. The above subject matter of this paragraph characterizes Example 86 of the present disclosure, which also includes subject matter according to Examples 84 or 85 above.

[0199]

[0226] By connecting the engagement surface 1020 to the integral precursor test coupon 100 and orienting the longitudinal tool axis 1004 parallel to the longitudinal axis of symmetry 106 of the integral precursor test coupon 100, the tooth portion 1010 can slide between the runners 130 of the integral precursor test coupon 100 so that the shear surface 1014 is precisely aligned with the flash 180 of the gauge portion 120.

[0200]

[0227] 12A-12D in general, and e.g., FIG. 10C and FIG. 10D in particular, the method 1200 further includes inserting (block 1209) the tool body 1002 between the two runners 130. The above subject matter of this paragraph characterizes Example 87 of the present disclosure, which also includes subject matter according to Example 86 above.

[0201]

[0228] Inserting the tool body 1002 between the two runners 130 allows the teeth 1010 to slide between the runners 130 of the integral precursor test coupon 100 so that the shear surface 1014 is precisely aligned with the flash 180 of the gauge portion 120.

[0202]

[0229] 12A-12D in general, and with particular reference to, for example, Figures 10D and 10E, according to method 1200, orienting the longitudinal tool axis 1004 parallel to the longitudinal axis of symmetry 106 of the integral precursor test coupon 100 (block 1214) includes circumferentially moving the shear surface 1014 away from the flash 180 (block 1218), and shearing the flash 180 (block 1236) includes rotating the tool body 1002 about the longitudinal axis of symmetry 106 (block 1238) such that the shear surface 1014 moves circumferentially toward and into contact with the flash 180. The above subject matter of this paragraph characterizes Example 88 of the present disclosure, which also includes subject matter according to Examples 86 or 87 above.

[0203]

[0230] By moving the shear surface 1014 circumferentially away from the flash 180 (as shown at position 1001 in FIG. 10E ) and then rotating the tool body 1002 about the longitudinal axis of symmetry 106 (as shown by the large curved arrow in FIG. 10D ) so that the shear surface 1014 moves circumferentially toward and into contact with the flash 180 (as shown at position 1003 in FIG. 10E ), the flash removal tool 1000 can be inserted between a pair of runners 130 and used to remove the flash 180 without interference between the tool body 1002 and the runners 130.

[0204]

[0231] 12A-12D generally, and for example, with reference to Figures 10D and 10E in particular, flash 180 has multiple portions each radially aligned with a respective one of the runners 130, and according to method 1200, rotating tool body 1002 (block 1238) includes shearing one of the multiple portions of flash 180 (block 1240) before tool body 1002 contacts the respective one of the runners 130. The above subject matter of this paragraph characterizes Example 89 of the present disclosure, which also includes subject matter according to Example 88 above.

[0205]

[0232] The flash removal tool 1000 can be used to remove flash 180 radially aligned with the runners 130 by rotating the tool body to shear one of the portions of flash 180 before the tool body 1002 contacts a respective one of the runners 130. For example, the mold 800 includes a runner cavity 830 defined between each pair of mold sections 860 (shown in FIGS. 8A, 8B, 8E, and 8F) to reduce or eliminate interference of the runners 130 formed in the runner cavity 830 with the mold sections 860 during disassembly of the mold sections 860. This arrangement of the runner cavities 830 ensures that a portion of the flash 180 formed by infiltration of the feedstock material 750 between the parting faces 870 of the mold sections 860 is radially aligned with each runner 130 relative to the radial direction 132. The radial direction 132 is defined relative to a cross-section of the intermediate portion 114 along the longitudinal axis of symmetry 106, as shown in Figure 10E. For example, the teeth 1010 may protrude from the tool body 1002 in a first direction 1090 and have a shear surface 1014 located at an offset distance 1012 away from the longitudinal tool axis 1004 in a second direction 1092, allowing the teeth 1010 to slide between the runners 130 such that the shear surface 1014 can contact the flash 180 under one of the runners 130 when the tool body 1002 is inserted between the runners 130.

[0206]

[0233] 12A-12D in general, and in particular, for example, in FIGS. 10C and 10D, the flash removal tool 1000 further includes a locating groove 1006 defined in the tool body 1002 and extending longitudinally between the engagement surface 1020 and the tines 1010. According to the method 1200, orienting the longitudinal tool axis 1004 parallel to the longitudinal axis of symmetry 106 of the integral precursor test coupon 100 (block 1214) includes receiving a portion of the integral precursor test coupon 100 in the locating groove 1006 (block 1222). The above-mentioned subject matter of this paragraph characterizes Example 90 of the present disclosure, which also includes subject matter according to any one of Examples 84 to 89 above.

[0207]

[0234] Receiving a portion of the integral precursor testing coupon 100 in the positioning groove 1006 facilitates stable positioning of the flash removal tool 1000 relative to the integral precursor testing coupon 100 .

[0208]

[0235] 12A-12D in general, and particularly, for example, with reference to Figures 10C and 10D, according to method 1200, coupling an engagement surface 1020 of a flash removal tool 1000 to a first precursor coupon end 102 (block 1210) includes coupling a longitudinal end wall 1034 of a positioning groove 1006 to the first precursor coupon end 102 of a unitary precursor test coupon 100 (block 1212). The above subject matter of this paragraph characterizes Example 91 of the present disclosure, which also includes subject matter according to Example 90 above.

[0209]

[0236] By connecting the longitudinal end wall 1034 of the positioning groove 1006 to the first precursor coupon end 102 of the integral precursor test coupon 100, the step of longitudinally positioning the tooth portion 1010 by connecting the engagement surface 1020 to the first precursor coupon end 102 is combined with the step of stably positioning the flash removal tool 1000 relative to the integral precursor test coupon 100, facilitating faster execution of the method 1200.

[0210]

[0237] 12A-12D in general, and for example, with reference to FIGS. 10C and 10D in particular, the one-piece precursor test coupon 100 further includes a first gripping portion 110, a second gripping portion 112, and an intermediate portion 114 interconnecting the first gripping portion 110 and the second gripping portion 112. The intermediate portion 114 includes a gauge portion 120, and the locating groove 1006 includes a cylindrically contoured portion 1030 extending parallel to the longitudinal tool axis 1004. According to the method 1200, receiving a portion of the one-piece precursor test coupon 100 in the locating groove 1006 (block 1222) includes coupling the cylindrically contoured portion 1030 of the locating groove 1006 to the first gripping portion 110 (block 1224). The preceding subject matter of this paragraph characterizes Example 92 of the present disclosure, which also includes subject matter according to Examples 90 or 91 above.

[0211]

[0238] Interlocking the cylindrically contoured portion 1030 of the positioning groove 1006 to the first gripping portion 110 facilitates stable positioning of the flash removal tool 1000 relative to the integral precursor test coupon 100 for embodiments in which the first gripping portion 110 has a cylindrical profile complementary to the cylindrically contoured portion 1030.

[0212]

[0239] 12A-12D in general, and for example, with particular reference to FIGS. 10C and 10D, the locating groove 1006 further includes a tapered portion 1032 that is parallel to the longitudinal tool axis 1004 and extends longitudinally between the cylindrically contoured portion 1030 and the tines 1010. According to method 1200, receiving a portion of the integral precursor test coupon 100 in the locating groove 1006 (block 1222) further includes coupling the tapered portion 1032 of the locating groove 1006 to the intermediate portion 114 (block 1226). The above subject matter of this paragraph characterizes Example 93 of the present disclosure, which also includes subject matter according to Example 92 above.

[0213]

[0240] Connecting the tapered portion 1032 of the positioning groove 1006 to the intermediate portion 114 facilitates stable positioning of the flash removal tool 1000 relative to the integral precursor test coupon 100 for embodiments in which the intermediate portion 114 adjacent to the first gripping portion 110 has a longitudinally tapered profile complementary to the tapered portion 1032.

[0214]

[0241] 12A-12D in general, and for example, in particular, with reference to FIGS. 10C and 10D, the flash removal tool 1000 further includes an auxiliary groove 1035 defined in the tool body 1002. The teeth 1010 divide the tool body 1002 longitudinally into two sides. The locating groove 1006 extends longitudinally through one of the two sides, and the auxiliary groove 1035 extends longitudinally through the other of the two sides and faces in a first direction 1090. According to the method 1200, orienting the longitudinal tool axis 1004 parallel to the longitudinal axis of symmetry 106 of the integral precursor test coupon 100 (block 1214) further includes receiving an additional portion of the integral precursor test coupon 100 in the auxiliary groove 1035 (block 1230). The above subject matter of this paragraph characterizes Example 94 of the present disclosure, which also includes the subject matter according to any one of Examples 90 to 93 above.

[0215]

[0242] ] Receiving another portion of the integral precursor testing coupon 100 in the auxiliary groove 1035 further facilitates stable positioning of the flash removal tool 1000 relative to the integral precursor testing coupon 100 .

[0216]

[0243] 12A-12D in general, and in particular, for example, in FIGS. 10C and 10D, the one-piece precursor test coupon 100 further includes a first gripping portion 110, a second gripping portion 112, and an intermediate portion 114 interconnecting the first gripping portion 110 and the second gripping portion 112. The auxiliary groove 1035 includes a cylindrically contoured auxiliary portion 1036 extending parallel to the longitudinal tool axis 1004. According to the method 1200, receiving the additional portion of the one-piece precursor test coupon 100 in the auxiliary groove 1035 (block 1230) includes connecting the cylindrically contoured auxiliary portion 1036 of the auxiliary groove 1035 to the second gripping portion 112 (block 1232). The above-mentioned subject matter of this paragraph characterizes Example 95 of the present disclosure, which also includes subject matter according to Example 94 above.

[0217]

[0244] Connecting the cylindrically contoured auxiliary portion 1036 of the auxiliary groove 1035 to the second gripping portion 112 further facilitates stable positioning of the flash removal tool 1000 relative to the integral precursor test coupon 100 for embodiments in which the second gripping portion 112 has a cylindrical profile complementary to the cylindrically contoured auxiliary portion 1036.

[0218]

[0245] 12A-12D in general, and in particular, for example, in FIGS. 10C and 10D, the auxiliary groove 1035 further includes a tapered auxiliary portion 1038 that is parallel to the longitudinal tool axis 1004 and extends longitudinally between the cylindrically contoured auxiliary portion 1036 and the tines 1010. According to method 1200, receiving an additional portion of the integral precursor test coupon 100 in the positioning groove 1035 (block 1230) further includes coupling the tapered auxiliary portion 1038 of the auxiliary groove 1035 to the intermediate portion 114 (block 1234). The above-mentioned subject matter of this paragraph characterizes Example 96 of the present disclosure, which also includes subject matter according to Example 95 above.

[0219]

[0246] Connecting the tapered auxiliary portion 1038 of the auxiliary groove 1035 to the intermediate portion 114 further facilitates stable positioning of the flash removal tool 1000 relative to the integral precursor test coupon 100 for embodiments in which the intermediate portion 114 adjacent the second gripping portion 112 has a longitudinally tapered profile complementary to the tapered auxiliary portion 1038.

[0220]

[0247] 12A-12D in general, and in particular, for example, in FIG. 1OE, according to method 1200, receiving a portion of integral precursor test coupon 100 in positioning groove 1006 (block 1222) includes maintaining gap 1018 between tool body 1002 and gauge portion 120 of flash removal tool 1000 (block 1228). The above subject matter of this paragraph characterizes Example 97 of the present disclosure, which also includes subject matter according to any one of Examples 90 to 96 above.

[0221]

[0248] Maintaining the gap 1018 between the tool body 1002 of the flash removal tool 1000 and the gauge portion 120 facilitates reducing or eliminating damage or scratches to the gauge portion 120 of the integral precursor test coupon 100 during removal of the flash 180. The integrity of the gauge portion 120 is necessary to enable accurate determination of material properties from testing of test coupons 900 (shown in FIG. 9 ) subsequently formed from the integral precursor test coupons 100. For example, the depth of the locating groove 1006, and in some instances, the depth of the auxiliary groove 1035, are selected to form the gap 1018 when the first gripping portion 110 is received in the locating groove 1006 and the second gripping portion 112 is received in the auxiliary groove 1035.

[0222]

[0249] 12A-12D in general, and particularly, for example, with reference to FIGS. 10C and 10D, the engagement surface 1020 is located a preselected distance 1022 away from the tines 1010 along the longitudinal tool axis 1004. According to method 1200, orienting the longitudinal tool axis 1004 parallel to the longitudinal axis of symmetry 106 of the integral precursor test coupon 100 (block 1214) includes longitudinally aligning the shear surface 1014 with the gauge portion 120 (block 1220). The above subject matter of this paragraph characterizes Example 98 of the present disclosure, which also includes subject matter according to any one of Examples 84 to 97 above.

[0223]

[0250] The engagement surface 1020 is positioned a preselected distance 1022 away from the tooth portion 1010 along the longitudinal axis 1004 such that when the engagement surface 1020 engages the integral precursor test coupon 100 and the longitudinal tool axis 1004 is aligned with the longitudinal axis of symmetry 106, the shear surface 1014 can be longitudinally aligned with the gauge portion 120.

[0224]

[0251] 12A-12D in general, and with particular reference to, for example, Figures 10A and 10C, the method 1200 further includes adjusting the preselected distance 1022 (block 1202) prior to orienting the longitudinal tool axis 1004 parallel to the longitudinal axis of symmetry 106 of the unitary precursor test coupon 100 (block 1214). The above subject matter of this paragraph characterizes Example 99 of the present disclosure, which also includes subject matter according to Example 98 above.

[0225]

[0252] Adjusting the preselected distance 1022 prior to use with the integral precursor test coupons 100 facilitates adapting the flash removal tool 1000 to integral precursor test coupons 100 having different sizes. For example, the integral precursor test coupons 100 are manufactured in different longitudinal sizes corresponding to the different sizes of test coupons 900 required for use with different material property testers (not shown). The adjustable preselected distance 1022 allows a single tool, such as the flash removal tool 1000, to be used with integral precursor test coupons 100 of multiple sizes.

[0226]

[0253] 12A-12D in general, and for example, in particular, FIG. 10A, a flash removal tool 1000 includes a telescoping portion 1040 coupled to a tool body 1002 and an engagement surface 1020 defined on the telescoping portion 1040. According to the method 1200, adjusting the preselected distance 1022 (block 1202) includes repositioning the telescoping portion 1040 relative to the tool body 1002 along the longitudinal tool axis 1004 (block 1204). The above subject matter of this paragraph characterizes embodiment 100 of the present disclosure, which also includes subject matter according to embodiment 99 above.

[0227]

[0254] Repositioning the telescoping portion 1040 relative to the tool body 1002 provides a mechanically simple embodiment for adjusting the preselected distance 1022.

[0228]

[0255] 12A-12D in general, and for example, in particular, with reference to FIG. 10A , according to method 1200, adjusting the preselected distance 1022 (block 1202) further includes selectively locking (block 1206) the telescoping portion 1040 in place relative to the tool body 1002 after repositioning (block 1204) the telescoping portion 1040 relative to the tool body 1002 along the longitudinal tool axis 1004. The above subject matter in this paragraph characterizes embodiment 101 of the present disclosure, which also includes subject matter according to embodiment 100 above.

[0229]

[0256] Selective locking of telescoping portion 1040 facilitates stability and simplicity of use of flash removal tool 1000 after adjustment of preselected distance 1022 .

[0230]

[0257] 12A-12D in general, and FIG. 10A in particular, for example, a detent 1044 is located on one of the telescoping portion 1040 or the tool body 1002, and a plurality of catches 1046 are longitudinally disposed on another one of the telescoping portion 1040 or the tool body 1002. According to the method 1200, selectively locking the telescoping portion 1040 in place relative to the tool body 1002 (block 1206) includes interfering with the detent 1044 with one of the plurality of catches 1046 (block 1208). The above-mentioned subject matter of this paragraph characterizes an embodiment 102 of the present disclosure, which also includes subject matter according to embodiment 101 above.

[0231]

[0258] Interfering with one of a number of catches 1046 corresponding to the preselected distance 1022 provides a mechanically simple and effective embodiment of locking the telescoping portion 1040 .

[0232]

[0259] 12A-12D in general, and in particular, for example, in FIGS. 10B and 10E, the one-piece precursor test coupon 100 further includes a first gripping portion 110, a second gripping portion 112, and a middle portion 114 interconnecting the first gripping portion 110 and the second gripping portion 112. The one-piece precursor test coupon 100 also includes a runner 130 that directly interconnects the first gripping portion 110 and the second gripping portion 112 and is not directly connected to the middle portion 114. The middle portion 114 includes a gauge portion 120, and the flash 180 has multiple portions that are each radially aligned with a respective one of the runners 130. The flash removal tool 1000 further includes a second tine 1011. A longitudinal tool axis 1004 is located between the tines 1010 and the second tines 1011. According to method 1200, shearing the flashing 180 from the gauge portion 120 (block 1236) includes shearing a first portion of the portion of the flashing 180 having the teeth 1010 and a second portion of the portion of the flashing 180 having the second teeth 1011 (block 1242). The above subject matter of this paragraph characterizes Example 103 of the present disclosure, which also includes subject matter according to any one of Examples 84 to 102 above.

[0233]

[0260] Shearing a first portion of the flash 180 having the teeth 1010 and a second portion of the flash 180 having the second teeth 1011 facilitates removal of multiple portions of the flash 180 without requiring disengagement of the flash removal tool 1000 from the integral precursor test coupon 100 and subsequent repositioning of the flash removal tool 1000 and thus the teeth 1010 adjacent the second portion of the flash 180, facilitating increased removal rates of the flash 180 from the integral precursor test coupon 100.

[0234]

[0261] 12A-12D generally, and for example, with particular reference to FIG. 10E, according to method 1200, shearing flash 180 from gauge portion 120 (block 1236) includes shearing flash 180 from unitary precursor test coupon 100 in the green state (block 1244). The above subject matter of this paragraph characterizes Example 104 of the present disclosure, which also includes subject matter according to any one of Examples 84 through 103 above.

[0235]

[0262] Shearing the flash 180 from the unitary precursor test coupon 100 in the green state simplifies removal of the flash 180 from the unitary precursor test coupon 100 due to the lack of structural strength of the unitary precursor test coupon 100 in the green state compared to the final material state. The unitary precursor test coupon 100 remains in the green state until it is subjected to a debonding process, which results in transformation to the Brownian state.

[0236]

[0263] 12A-12D generally, and for example, with particular reference to FIG. 10E, according to method 1200, shearing flash 180 from gauge portion 120 (block 1236) includes shearing flash 180 from integral precursor test coupon 100 in the brown state (block 1246). The above subject matter of this paragraph characterizes Example 105 of the present disclosure, which also includes subject matter according to any one of Examples 84 through 103 above.

[0237]

[0264] Shearing the flash 180 from the unitary precursor test coupon 100 in the brown state simplifies removal of the flash 180 from the unitary precursor test coupon 100 due to the lack of structural strength of the unitary precursor test coupon 100 in the brown state compared to the final material state. Upon debonding, the unitary precursor test coupon 100 remains in the brown state until it is subjected to a sintering process which results in transformation to the final material state.

[0238]

[0265] 12A-12D generally, and for example, with particular reference to FIG. 10E, according to method 1200, shearing flash 180 from gauge portion 120 (block 1236) includes shearing flash 180 from the final material state of unitary precursor test coupon 100 (block 1248). The above subject matter of this paragraph characterizes Example 106 of the present disclosure, which also includes subject matter according to any one of Examples 84 through 103 above.

[0239]

[0266] Shearing the flash 180 from the integral precursor test coupon 100 in its final material state facilitates reducing or eliminating the risk of damage to the gauge portion 120 due to the increased structural strength of the integral precursor test coupon 100 compared to its final material state.

[0240]

[0267] 12A-12D generally, and for example, FIG. 10E in particular, the one-piece precursor test coupon 100 further includes a first gripping portion 110, a second gripping portion 112, and a middle portion 114 interconnecting the first gripping portion 110 and the second gripping portion 112. The one-piece precursor test coupon 100 also includes a runner 130 that directly interconnects the first gripping portion 110 and the second gripping portion 112 and is not directly connected to the middle portion 114. The middle portion 114 includes a gauge portion 120, and a flash 180 has a plurality of portions each radially aligned with a respective one of the runners 130. According to the method 1200, shearing the flash 180 from the gauge portion 120 (block 1236) includes shearing a first portion of a portion of the flash 180 (block 1250). The above subject matter of this paragraph characterizes Example 107 of the present disclosure, which also includes the subject matter according to any one of Examples 84 to 106 above.

[0241]

[0268] Shearing a first portion of a portion of the flash 180 that is radially aligned with one of the runners 130 facilitates maintaining the integrity of the runner 130 during flash removal, which in turn increases the structural stability of the integral precursor test coupon 100 during flash removal, particularly if, for example, the integral precursor test coupon 100 is in a green or brown state during flash removal.

[0242]

[0269] 12A-12D generally, and for example, with particular reference to FIGS. 10C-10E, the method 1200 further includes, after shearing off a first portion of the portion of the flashing 180 (block 1250), removing the flashing removal tool 1000 from between the first adjacent pair of runners 130 (block 1254), repositioning the flashing removal tool 1000 between a second adjacent pair of runners 130 (block 1256), and shearing off a second portion of the portion of the flashing 180 from the gauge portion 120 by the shear surface 1014 (block 1258). The above-mentioned subject matter of this paragraph characterizes Example 108 of the present disclosure, which also includes subject matter according to Example 107 above.

[0243]

[0270] Repositioning the flash removal tool 1000 between a second adjacent pair of runners 130 and shearing off a second portion of the flash that is radially aligned with the other runner 130 facilitates maintaining the integrity of the runners 130 during flash removal using the flash removal tool 1000 having a single tooth portion 1010, simplifying manufacture and maintenance of the flash removal tool 1000.

[0244]

[0271] 12A-12D generally, and for example, with reference to FIGS. 9 and 10E in particular, the one-piece precursor testing coupon 100 further includes a first gripping portion 110, a second gripping portion 112, and a middle portion 114 interconnecting the first gripping portion 110 and the second gripping portion 112. The one-piece precursor testing coupon 100 also includes a runner 130 that directly interconnects the first gripping portion 110 and the second gripping portion 112 and is not directly connected to the middle portion 114. The middle portion 114 of the one-piece precursor testing coupon 100 includes a gauge portion 120. The method 1200 further includes removing the runner 130 from the one-piece precursor testing coupon 100 (block 1252). According to method 1200, shearing flash 180 from gauge portion 120 (block 1236) is performed prior to removing runner 130 from integral precursor test coupon 100 (block 1252). The above subject matter of this paragraph characterizes Example 109 of the present disclosure, which also includes subject matter according to any one of Examples 84 through 108 above.

[0245]

[0272] Shearing the flash 180 prior to removal of the runner 130 increases the structural stability of the integral precursor test coupon 100 during flash removal, particularly if, for example, the integral precursor test coupon 100 is in a green or brown state during flash removal.

[0246]

[0273] 12A-12D generally, and for example, with reference to FIGS. 9 and 10E in particular, the one-piece precursor testing coupon 100 further includes a first gripping portion 110, a second gripping portion 112, and a middle portion 114 interconnecting the first gripping portion 110 and the second gripping portion 112. The one-piece precursor testing coupon 100 also includes a runner 130 that directly interconnects the first gripping portion 110 and the second gripping portion 112 and is not directly connected to the middle portion 114. The middle portion 114 of the one-piece precursor testing coupon 100 includes a gauge portion 120. The method 1200 further includes removing the runner 130 from the one-piece precursor testing coupon 100 (block 1252). According to method 1200, shearing flash 180 from gauge portion 120 (block 1236) is performed after removing runner 130 from integral precursor test coupon 100 (block 1252). The above subject matter of this paragraph characterizes Example 110 of the present disclosure, which also includes subject matter according to any one of Examples 84 to 108 above.

[0247]

[0274] Shearing the flash 180 after removal of the runner 130 facilitates reducing or eliminating interference of the runner 130 with the flash removal tool 1000 while maintaining the ease of alignment provided by the flash removal tool 1000.

[0248]

[0275] An embodiment of the disclosure may be described in the context of an aircraft manufacturing and service method 1300 shown in FIG. 13 and an aircraft 1302 shown in FIG. 14. During pre-production, the example method 1300 may include specification and design (block 1304) and material procurement (block 1306) of the aircraft 1302. During production, manufacturing of components and subassemblies (block 1308) and system integration (block 1310) of the aircraft 1302 may occur. The aircraft 1302 may then undergo certification and delivery (block 1312) and be placed into service (block 1314). During operation, the aircraft 1302 may be scheduled for routine maintenance and upkeep (block 1316). The routine maintenance and upkeep may include modification, reconfiguration, retrofitting, etc. of one or more systems of the aircraft 1302.

[0249]

[0276] Each process of example method 1300 may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). As used herein, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors, a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers, and an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0250]

[0277] As shown in FIG. 14 , an aircraft 1302 produced by example method 1300 may include an airframe 1318 having a number of high level systems 1320 and an interior 1322. Examples of high level systems 1320 include one or more of a propulsion system 1324, an electrical system 1326, a hydraulic system 1328, and an environmental system 1330. Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. As such, the principles disclosed herein may be applied to other vehicles (e.g., land vehicles, marine vehicles, space vehicles, etc.) in addition to the aircraft 1302.

[0251]

[0278] The apparatus and methods shown or described herein may be utilized during any one or more stages of the manufacturing and service method 1300. For example, components or subassemblies corresponding to the manufacturing of components and subassemblies (block 1308) may be fabricated or manufactured in a manner similar to components or subassemblies manufactured during operation of the aircraft 1302 (block 1314). Also, one or more examples of the apparatus(es), method(s), or combinations thereof may be utilized during the manufacturing stages 1308 and 1310, for example, by significantly streamlining or reducing the cost of assembling the aircraft 1302. Similarly, one or more embodiments implementing the apparatus or method, or combinations thereof, may be utilized during operation of the aircraft 1302 (block 1314) and / or during maintenance and service (block 1316), for example, but not by way of limitation.

[0252]

[0279] Various embodiments of the devices and methods disclosed herein include a variety of components, features, and functions. It should be understood that the various embodiments of the devices and methods disclosed herein may include any of the components, features, and functions of any other embodiments of the devices and methods disclosed herein, in any combination, and all such possibilities are intended to be within the scope of the present disclosure.

[0253]

[0280] Many modifications of the embodiments set forth herein will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the above descriptions and the associated drawings.

[0254]

[0281] It should therefore be understood that the present disclosure should not be limited to the specific examples illustrated, and that modifications and other examples are intended to be included within the scope of the appended claims. Moreover, while in the above description and the associated drawings, examples of the present disclosure have been described in terms of specific example combinations of elements and / or functions, it should be understood that alternative embodiments can provide different combinations of elements and / or functions without departing from the scope of the appended claims. Thus, in the appended claims, reference numerals enclosed in parentheses are provided for illustrative purposes only and are not intended to limit the scope of the claimed subject matter to the specific examples provided in the present disclosure.

Claims

1. A first gripping portion (110); A second gripping portion (112); an intermediate portion (114) interconnecting the first gripping portion (110) and the second gripping portion (112); a runner (130) directly interconnecting the first gripping portion (110) and the second gripping portion (112) and not directly connected to the intermediate portion (114); Including, the first gripping portion (110), the second gripping portion (112), the intermediate portion (114), and the runner (130) are made of a material (150) including a metal powder (748); A monolithic precursor test coupon (100) for tensile testing, said material (150) being in a green state.

2. 2. The integral precursor test coupon (100) of claim 1, wherein the first gripping portion (110), the intermediate portion (114), and the second gripping portion (112) extend continuously along a longitudinal axis of symmetry (106) from a first precursor coupon end (102) to a second precursor coupon end (104) and together define a precursor coupon body (108).

3. 3. The integral precursor test coupon (100) of claim 2, wherein the first gripping portion (110) and the second gripping portion (112) have the same order of symmetry about the longitudinal axis of symmetry (106).

4. the intermediate portion (114) includes a gauge portion (120); the gauge section (120) has a gauge section cross section perpendicular to the longitudinal axis of symmetry (106); 4. The integral precursor test coupon (100) of claim 2 or 3, wherein the gauge portion cross-section is smaller than the cross-sectional area perpendicular to the longitudinal axis of symmetry (106) of all portions of the intermediate portion (114) other than the gauge portion (120).

5. 5. The integral precursor test coupon of claim 4, wherein a surface (116) of the intermediate portion (114) has a linear contour in a plane containing the longitudinal axis of symmetry (106) that defines a first curvature (302) adjacent the first gripping portion (110), a second curvature (304) adjacent the second gripping portion (112), and the gauge portion (120) over a gauge length (122) between the first curvature (302) and the second curvature (304).

6. 5. The integral precursor test coupon (100) of claim 4, wherein a surface (116) of the intermediate portion (114) has a continuous curvature (306) between the first gripping portion (110) and the second gripping portion (112) such that the gauge portion (120) lies in a plane perpendicular to the longitudinal axis of symmetry (106).

7. the intermediate portion (114) further comprises a notch (400); The integral precursor test coupon (100) of any one of claims 4 to 6, wherein the notch (400) comprises the gauge portion (120).

8. The notch (400) is disposed in a plane containing the longitudinal axis of symmetry (106): an angular profile (402) along said longitudinal axis of symmetry (106); an arcuate profile (404) along said longitudinal axis of symmetry (106); or A rectangular profile (406) along said longitudinal axis of symmetry (106). The integral precursor test coupon (100) of claim 7, comprising one of:

9. 9. The integral precursor test coupon (100) of claim 7 or 8, wherein the notch (400) is symmetrical about the longitudinal axis of symmetry (106).

10. 9. The integral precursor test coupon (100) of claim 7 or 8, wherein the notch (400) is not symmetrical about the longitudinal axis of symmetry (106).

11. 11. The integral precursor test coupon (100) of any one of claims 2 to 10, wherein some of the runners of a pair of adjacent runners (130) and some of the runners of any other pair of adjacent runners (130) have equal angular separation around the longitudinal axis of symmetry (106).

12. 12. The integral precursor test coupon (100) of any one of claims 2 to 11, wherein a total length (500) of the integral precursor test coupon (100) measured along the longitudinal axis of symmetry (106) is between 4 inches (10.1 cm) and 12 inches (30.5 cm), and a length (514) of the intermediate portion (114) is between 1 inch (2.5 cm) and 6 inches (15.2 cm).

13. 13. The integral precursor test coupon (100) of claim 12, wherein a gripping diameter (510) of each of the first gripping portion (110) and the second gripping portion (112) is between 0.25 cm (0.1 inch) and 3.0 cm (1.2 inch), and a minimum diameter (515) of the intermediate portion (114) is between 0.51 cm (0.2 inch) and 1.52 cm (0.6 inch).

14. 14. The integral precursor test coupon (100) of claim 12 or 13, wherein each of the runners (130) has a radius of curvature (530) in a plane containing the longitudinal axis of symmetry (106) of between 7.6 cm (3 inches) and 28.0 cm (11 inches).

15. 15. The integral precursor test coupon (100) of any one of claims 12 to 14, wherein each of the runners (130) defines a runner thickness (531) measured in a plane and intersecting the intermediate portion (114), the runner thickness (531) being between 0.25 cm (0.1 inch) and 1.52 cm (0.6 inch).

Images