Titanium MIM Composition with Ceramic Interlayer for Uniform Binder Distribution
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Solution Overview
Problem
Titanium powders used in metal powder injection molding (MIM) methods face challenges in uniform mixing with organic binders, leading to uneven distribution and molding defects, especially in areas with rapid wall thickness changes or near mold gates.
Innovation Solution
An injection molding composition is developed, comprising a titanium-based powder with an average particle diameter of 15 μm to 35 μm, a ceramic powder with an average particle diameter of 1 nm to 100 nm, and an organic binder. The ceramic powder is interposed between the titanium-based powder particles, improving mixing uniformity and fluidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If titanium powder is mixed with organic binder in conventional MIM method, then molding material is formed, but uneven distribution of organic binder occurs leading to molding defects
Solution Approach 1:
The patent introduces a surface-treated titanium powder where the organic binder is pre-adsorbed onto the powder surface. This surface treatment acts as an intermediary mechanism that ensures uniform distribution of the organic binder throughout the molding material, preventing the uneven distribution that normally occurs in conventional mixing methods.
Solution Approach 2:
The organic binder is applied to the titanium powder surface before mixing with other components. This preliminary action of pre-coating the powder particles ensures that the binder is evenly distributed from the start, preventing aggregation and ensuring uniform mixing throughout the molding process.
2Manufacturing precision
If titanium powder is used in MIM method, then titanium sintered body can be produced, but surface properties such as metallic luster and aesthetic appearance are deteriorated due to binder uneven distribution
Solution Approach 1:
The surface-treated titanium powder serves as an intermediary that prevents binder aggregation. By pre-adsorbing the organic binder onto the powder surface, the treatment ensures uniform distribution during mixing, which directly prevents surface defects and maintains metallic luster and aesthetic appearance in the final sintered body.
3Manufacturing precision
If conventional mixing method is used for titanium powder and organic binder, then molding material is prepared, but quantitative balance between titanium powder and organic binder is lost
Solution Approach 1:
The organic binder is pre-applied to the titanium powder surface at a controlled amount before mixing. This preliminary action ensures that the quantitative balance is maintained from the start, preventing the loss of composition uniformity that occurs during conventional mixing where binder aggregation can occur.
Data Source
AI summary
An injection molding composition contains a titanium-based powder containing titanium as a main component and having an average particle diameter of 15 μm or more and 35 μm or less, a ceramic powder containing a ceramic as a main material and having an average particle diameter of 1 nm or more and 100 nm or less, and an organic binder. The ceramic is an oxide-based ceramic containing an oxide as a main component, and a standard free energy of formation of the oxide at 1000° C. may be lower than a standard free energy of formation of titanium oxide at 1000° C.