Densification and microstructural development during sintering of powder injection molded Fe micro–nanopowder

Research Progress on Low-Pressure Powder Injection Molding

Powder injection molding (PIM) is a well-known technique to manufacture net-shaped, complicated, macro or micro parts employing a wide range of materials and alloys. Depending on the pressure applied to inject the feedstock, this process can be separated into low-pressure (LPIM) and high-pressure (HPIM) injection molding. Although the LPIM and HPIM processes are theoretically similar, all steps have substantial differences, particularly feedstock preparation, injection, and debinding. After decades of focusing on HPIM, low-viscosity feedstocks with improved flowability have recently been produced utilizing low-molecular-weight polymers for LPIM. It has been proven that LPIM can be used for making parts in low quantities or mass production. Compared to HPIM, which could only be used for the mass production of metallic and ceramic components, LPIM can give an outstanding opportunity to cover applications in low or large batch production rates. Due to the use of low-cost equipment, LPIM also provides several economic benefits. However, establishing an optimal binder system for all powders that should be injected at extremely low pressures (below 1 MPa) is challenging. Therefore, various defects may occur throughout the mixing, injection, debinding, and sintering stages. Since all steps in the process are interrelated, it is important to have a general picture of the whole process which needs a scientific overview. This paper reviews the potential of LPIM and the characteristics of all steps. A complete academic and research background survey on the applications, challenges, and prospects has been indicated. It can be concluded that although many challenges of LPIM have been solved, it could be a proper solution to use this process and materials in developing new applications for technologies such as additive manufacturing and processing of sensitive alloys.

Carbon-coated iron nanopowder as a sintering aid for water-atomized iron powder

The paper examines the influence of carbon coating on iron nanopowder used as a sintering aid for water-atomized iron powder. Iron nanopowder without such a coating was used as a reference sintering aid to isolate the influence of the carbon coating. Both nanopowder variants were characterised using XPS and HRTEM. The results showed a core–shell structure for both variants. The iron nanopowder is covered by a 3–4 nm thick iron oxide layer, while the carbon-coated iron nanopowder is encapsulated with several nanometric carbon layers. Thermogravimetry conducted in a pure hydrogen environment shows a multipeak behaviour for the carbon-coated iron nanopowder, while a single peak behaviour is observed for the iron nanopowder. Two types of micro/nanobimodal powders were obtained by mixing the nanopowder with water-atomized iron powder. Improved linear shrinkage was observed during sintering when the carbon-coated iron nanopowder was added. This can be explained by the reduction in surface diffusion in the nanopowder caused by the carbon coating, which allows the nanopowder to sinter at higher temperatures and improves densification. Carbon and oxygen analysis, density measurements, optical microscopy and JMatPro calculations were also performed.

Effect of Thermal Debinding Conditions on the Sintered Density of Low-Pressure Powder Injection Molded Iron Parts

Low-pressure powder injection molding (LPIM) is a cost-effective technology for producing intricate small metal parts at high, medium, and low production volumes in applications which, to date, have involved ceramics or spherical metal powders. Since the use of irregular metal powders represents a promising way to reduce overall production costs, this study aims to investigate the potential of manufacturing powder injection molded parts from irregular commercial iron powders using the LPIM approach. To this end, a low viscosity feedstock was injected into a rectangular mold cavity, thermally wick-debound using three different pre-sintering temperatures, and finally sintered using an identical sintering cycle. During debinding, an increase in pre-sintering temperature from 600 to 850 °C decreased the number of fine particles. This decreased the sintered density from 6.2 to 5.1 g/cm3, increased the average pore size from 9 to 14 μm, and decreased pore circularity from 67 to 59%.

What We Should Consider for Full Densification when Sintering

To fully densify a powder compact, we should avoid two things: (i) entrapment of insoluble gases within pores and (ii) entrapment of isolated pores within grains. This paper describes general directions for promoting full densification in view of the above two points. Emphasis is placed on ways to potentially prevent pore entrapment in terms of grain growth control. Currently available techniques that can enhance densification while suppressing grain growth are briefly described, and their major mechanisms are discussed.

Analysis of Iron Oxide Reduction Kinetics in the Nanometric Scale Using Hydrogen

Iron nanopowder could be used as a sintering aid to water-atomised steel powder to improve the sintered density of metallurgical (PM) compacts. For the sintering process to be efficient, the inevitable surface oxide on the nanopowder must be reduced at least in part to facilitate its sintering aid effect. While appreciable research has been conducted in the domain of oxide reduction of the normal ferrous powder, the same cannot be said about the nanometric counterpart. The reaction kinetics for the reduction of surface oxide of iron nanopowder in hydrogen was therefore investigated using nonisothermal thermogravimetric (TG) measurements. The activation energy values were determined from the TG data using both isoconversional Kissinger–Akahira–Sunose (KAS) method and the Kissinger approach. The values obtained were well within the range of reported data. The reaction kinetics of Fe₂O₃ as a reference material was also depicted and the reduction of this oxide proceeds in two sequential stages. The first stage corresponds to the reduction of Fe₂O₃ to Fe₃O₄, while the second stage corresponds to a complete reduction of oxide to metallic Fe. The activation energy variation over the reduction process was observed and a model was proposed to understand the reduction of surface iron oxide of iron nanopowder.

Thermo-mechanical improvement of Inconel 718 using ex situ boron nitride-reinforced composites processed by laser powder bed fusion

Hexagonal boron nitride-reinforced Inconel 718 (h-BN/IN718) composites were fabricated using a laser powder bed fusion (LPBF) technique to treat a nanosheet-micropowder precursor mixture prepared in a mechanical blending process. Tailoring the BN in IN718 enhanced the thermal resistance of the composites, thereby dampening the sharpness of the melting temperature peak at 1364 °C. This is because the presence of the BN reinforcement, which has a low coefficient of thermal expansion (CTE), resulted in a heat-blocking effect within the matrix. Following this lead, we found that the BN (2.29 g/cm³) was uniformly distributed and strongly embedded in the IN718 (8.12 g/cm³), with the lowest alloy density value (7.03 g/cm³) being obtained after the addition of 12 vol% BN. Consequently, its specific hardness and compressive strength rose to 41.7 Hv_0.5·cm³/g and 92.4 MPa·cm³/g, respectively, compared to the unreinforced IN718 alloy with 38.7 Hv_0.5·cm³/g and 89.4 MPa·cm³/g, respectively. Most importantly, we discovered that the wear resistance of the composite improved compared to the unreinforced IN718, indicated by a decrease in the coefficient of friction (COF) from 0.43 to 0.31 at 2400 s. This is because the BN has an exfoliated surface and intrinsically high sliding and lubricating characteristics.

A review of biocompatible metal injection moulding process parameters for biomedical applications

Biocompatible metals have been revolutionizing the biomedical field, predominantly in human implant applications, where these metals widely used as a substitute to or as function restoration of degenerated tissues or organs. Powder metallurgy techniques, in specific the metal injection moulding (MIM) process, have been employed for the fabrication of controlled porous structures used for dental and orthopaedic surgical implants. The porous metal implant allows bony tissue ingrowth on the implant surface, thereby enhancing fixation and recovery. This paper elaborates a systematic classification of various biocompatible metals from the aspect of MIM process as used in medical industries. In this study, three biocompatible metals are reviewed-stainless steels, cobalt alloys, and titanium alloys. The applications of MIM technology in biomedicine focusing primarily on the MIM process setting parameters discussed thoroughly. This paper should be of value to investigators who are interested in state of the art of metal powder metallurgy, particularly the MIM technology for biocompatible metal implant design and development.

Bimodal NdNiAl and NdFeB hybrid catalytic and magnetic nanoparticles laminated on Fe foam: catalytic conversion of CO + 3H2 to CH4

For the production of CH₄ from CO hydrogenation, a hybrid foam with high catalytic activity and strong magnetic bonding ability was fabricated by electrospraying and co-sintering NdNiAl and NdFeB nanoparticles over a Fe foam.