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Aguilar-García JL, Lorenzo ET, Jimenez-Morales A, Ruíz-Navas EM. Design of Sustainable Aluminium-Based Feedstocks for Composite Extrusion Modelling (CEM). MATERIALS (BASEL, SWITZERLAND) 2024; 17:1093. [PMID: 38473565 DOI: 10.3390/ma17051093] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/19/2023] [Revised: 01/25/2024] [Accepted: 02/26/2024] [Indexed: 03/14/2024]
Abstract
Additive manufacturing (AM) has become one of the most promising manufacturing techniques in recent years due to the geometric design freedom that this technology offers. The main objective of this study is to explore Composite Extrusion Modelling (CEM) with aluminium as an alternative processing route for aluminium alloys. This process allows for working with pellets that are deposited directly, layer by layer. The aim of the technique is to obtain aluminium alloy samples for industrial applications with high precision, without defects, and which are processed in an environmentally friendly manner. For this purpose, an initial and preliminary study using powder injection moulding (PIM), necessary for the production of samples, has been carried out. The first challenge was the design of a sustainable aluminium-based feedstock. The powder injection moulding technique was used as a first approach to optimise the properties of the feedstock through a combination of water-soluble polymer, polyethyleneglycol (PEG), and cellulose acetate butyrate (CAB) wich produces low CO2 emissions. To do this, a microstructural characterisation was carried out and the critical solid loading and rheological properties of the feedstocks were studied. Furthermore, the debinding conditions and sintering parameters were adjusted in order to obtain samples with the required density for the following processes and with high geometrical accuracy. In the same way, the printing parameters were optimised for proper material deposition.
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Affiliation(s)
- José L Aguilar-García
- Powder Technology Group (GTP), Materials Science and Engineering Department, Álvaro Alonso Barba Institute (IAAB), Universidad Carlos III de Madrid, Avda. Universidad 30, 28911 Leganés, Spain
| | - Eduardo Tabares Lorenzo
- Powder Technology Group (GTP), Materials Science and Engineering Department, Álvaro Alonso Barba Institute (IAAB), Universidad Carlos III de Madrid, Avda. Universidad 30, 28911 Leganés, Spain
| | - Antonia Jimenez-Morales
- Powder Technology Group (GTP), Materials Science and Engineering Department, Álvaro Alonso Barba Institute (IAAB), Universidad Carlos III de Madrid, Avda. Universidad 30, 28911 Leganés, Spain
- CIBERINFEC-CIBER de Enfermedades Infecciosas, Instituto de Salud Carlos III, 28029 Madrid, Spain
| | - Elisa M Ruíz-Navas
- Powder Technology Group (GTP), Materials Science and Engineering Department, Álvaro Alonso Barba Institute (IAAB), Universidad Carlos III de Madrid, Avda. Universidad 30, 28911 Leganés, Spain
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Basir A, Muhamad N, Sulong AB, Amin MBM, Jamadon NH, Radzuan NAM. Micro-Injection Molding and Debinding Behavior of Hydroxyapatite/Zirconia Bi-Materials Fabricated by Two-Component Micro-Powder Injection Molding Process. MATERIALS (BASEL, SWITZERLAND) 2023; 16:6375. [PMID: 37834512 PMCID: PMC10573493 DOI: 10.3390/ma16196375] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/11/2023] [Revised: 09/12/2023] [Accepted: 09/21/2023] [Indexed: 10/15/2023]
Abstract
The micro-scale joining of two different materials using two-component micro-powder injection molding (2C-µPIM) is an intriguing technique. The formation of defects in bi-materials at different processing stages makes this technique challenging. This study presents the fabrication of defect-free bi-material micro-parts containing hydroxyapatite (HA) and 3 mol% yttria-stabilized zirconia (3YSZ) via 2C-µPIM. Critical powder volume concentrations (CPVCs) of 61.7 vol% and 47.1 vol% were obtained for the HA and 3YSZ powders, respectively. Based on the CPVCs, the optimal loadings for the HA and 3YSZ powders were selected as 60 vol% and 45 vol%, respectively. The HA and 3YSZ feedstocks were prepared by separately mixing the optimal powder contents with low-density polyethylene (LDPE) and palm stearin binders. The feedstocks displayed pseudoplastic behavior, and the lowest ranges of viscosity for the HA and 3YSZ at a temperature of 180 °C were 157.1-1392.5 Pa·s and 726.2-985.5 Pa·s, respectively. The feedstocks were injected to produce green HA/3YSZ micro-sized components. It was found that a solvent debinding temperature of 70 °C removed 60.6% of the palm stearin binder from the sample. In the thermal debinding stage, the open channels that formed in the bi-material sample's solvent debound at 70 °C and contributed to the removal of 93 to 95% of the binder system. When the debound bi-materials were sintered at 1300 °C, the highest relative density of 96.3% was obtained. The sintering operation revealed a linear shrinkage between 13 and 17% in the sintered HA/3YSZ micro-parts.
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Affiliation(s)
| | | | - Abu Bakar Sulong
- Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, Malaysia; (A.B.); (N.M.); (M.b.M.A.); (N.H.J.); (N.A.M.R.)
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Basir A, Muhamad N, Sulong AB, Jamadon NH, Foudzi FM. Recent Advances in Processing of Titanium and Titanium Alloys through Metal Injection Molding for Biomedical Applications: 2013-2022. MATERIALS (BASEL, SWITZERLAND) 2023; 16:ma16113991. [PMID: 37297124 DOI: 10.3390/ma16113991] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/16/2023] [Revised: 05/14/2023] [Accepted: 05/23/2023] [Indexed: 06/12/2023]
Abstract
Metal injection molding (MIM) is one of the most widely used manufacturing processes worldwide as it is a cost-effective way of producing a variety of dental and orthopedic implants, surgical instruments, and other important biomedical products. Titanium (Ti) and Ti alloys are popular modern metallic materials that have revamped the biomedical sector as they have superior biocompatibility, excellent corrosion resistance, and high static and fatigue strength. This paper systematically reviews the MIM process parameters that extant studies have used to produce Ti and Ti alloy components between 2013 and 2022 for the medical industry. Moreover, the effect of sintering temperature on the mechanical properties of the MIM-processed sintered components has been reviewed and discussed. It is concluded that by appropriately selecting and implementing the processing parameters at different stages of the MIM process, defect-free Ti and Ti alloy-based biomedical components can be produced. Therefore, this present study could greatly benefit future studies that examine using MIM to develop products for biomedical applications.
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Affiliation(s)
- Al Basir
- Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, Malaysia
| | - Norhamidi Muhamad
- Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, Malaysia
| | - Abu Bakar Sulong
- Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, Malaysia
| | - Nashrah Hani Jamadon
- Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, Malaysia
| | - Farhana Mohd Foudzi
- Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, Malaysia
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Oh H, Im T, Pyo J, Lee JS, Lee CS. Study of solid loading of feedstock using trimodal iron powders for extrusion based additive manufacturing. Sci Rep 2023; 13:4819. [PMID: 36964278 DOI: 10.1038/s41598-023-32095-5] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/05/2022] [Accepted: 03/22/2023] [Indexed: 03/26/2023] Open
Abstract
Volume loading of feedstock using trimodal iron (Fe) powders was investigated for the application of extrusion-based additive manufacturing (AM). Fe trimodal powder composed of nano, sub-nano, and micro particles was manufactured via the powder metallurgy process where small particles behave as rolling bearings among large particles, and thereby improving the flow characteristics of feedstock by minimizing friction among the particles. The flow behavior and microstructures of the monomodal feedstock were compared with those of the trimodal feedstock. We have confirmed that the critical powder loading of monomodal powder was measured to be 70 vol.% while trimodal powder showed up to 74 vol.%. Furthermore, trimodal feedstocks of 60, 65, 70, 75, and 80 vol.% Fe powder were prepared to determine the optimal powder content for sintering. As a result, the feedstock with powder content of 70 vol.% gave the highest sintered density of 92.32%, the highest Vickers hardness of 80.67 HV, with the smallest dimensional variation in shrinkage, proposing 70 vol.% of trimodal feedstock to be the suitable powder content for AM. Finally, its microstructural and mechanical comparison with 70 vol.% sintered part using monomodal Fe powder, showed that the sintered part using trimodal feedstock displayed higher hardness, uniform shrinkage as well as smaller grain size, confirming trimodal feedstock to be favorable for the application of extrusion-based AM.
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Affiliation(s)
- Heungseok Oh
- Department of Materials and Chemical Engineering, Hanyang University, Ansan, 15588, Republic of Korea
| | - Taehyeob Im
- Department of Materials and Chemical Engineering, Hanyang University, Ansan, 15588, Republic of Korea
| | - Jungsuk Pyo
- Department of Materials and Chemical Engineering, Hanyang University, Ansan, 15588, Republic of Korea
- Solueta Co. Ltd. R&D Center, Hwaseong, 18544, Republic of Korea
| | - Jai-Sung Lee
- Department of Materials and Chemical Engineering, Hanyang University, Ansan, 15588, Republic of Korea
| | - Caroline Sunyong Lee
- Department of Materials and Chemical Engineering, Hanyang University, Ansan, 15588, Republic of Korea.
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Liu C, Lu H, Qin M, Wu H, Zhang Z, He Q, Wang Y, Jia B, Qu X. Effect of powders on aluminum nitride components fabricated by PIM. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118409] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/09/2023]
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Momeni V, Hufnagl M, Shahroodi Z, Gonzalez-Gutierrez J, Schuschnigg S, Kukla C, Holzer C. Research Progress on Low-Pressure Powder Injection Molding. MATERIALS (BASEL, SWITZERLAND) 2022; 16:379. [PMID: 36614718 PMCID: PMC9822315 DOI: 10.3390/ma16010379] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 12/05/2022] [Revised: 12/25/2022] [Accepted: 12/28/2022] [Indexed: 06/17/2023]
Abstract
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.
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Affiliation(s)
- Vahid Momeni
- Polymer Processing, Montanuniversitaet Leoben, 8700 Leoben, Austria
| | | | - Zahra Shahroodi
- Polymer Processing, Montanuniversitaet Leoben, 8700 Leoben, Austria
| | - Joamin Gonzalez-Gutierrez
- Polymer Processing, Montanuniversitaet Leoben, 8700 Leoben, Austria
- Functional Polymers Research Unit, Materials Research and Technology (MRT) Department, Luxembourg Institute of Science and Technology (LIST), L-4940 Luxembourg, Luxembourg
| | | | - Christian Kukla
- Industrial Liaison Department, Montanuniversitaet Leoben, 8700 Leoben, Austria
| | - Clemens Holzer
- Polymer Processing, Montanuniversitaet Leoben, 8700 Leoben, Austria
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Cho H, Park JM, Kim JH, Lee C, Park DY, Rho J, Park SJ. Mass production of superhydrophilic micropatterned copper surfaces using powder injection molding process. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117779] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/16/2022]
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Fabrication of TiAl alloys turbocharger turbine wheel for engines by metal injection molding. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.01.070] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
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Côté R, Azzouni M, Demers V. Impact of binder constituents on the moldability of titanium-based feedstocks used in low-pressure powder injection molding. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2020.12.008] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
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Hu K, Zou L, Shi Q, Hu K, Liu X, Duan B. Effect of titanium hydride powder addition on microstructure and properties of titanium powder injection molding. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.03.059] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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The Technological Design of Geometrically Complex Ti-6Al-4V Parts by Metal Injection Molding. APPLIED SCIENCES-BASEL 2019. [DOI: 10.3390/app9071339] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
Abstract
In this study, the metal injection molding (MIM) process is applied to produce Ti-6Al-4V parts using blended and prealloyed powders, respectively. The feedstocks are prepared from a polyformaldehyde-based binder system with a powder loading of 60 vol%, exhibiting a low viscosity. The decomposition behavior of the binders is investigated and the thermal debinding procedure is designed accordingly. The debound parts are subsequently sintered at 1200 and 1300 °C. The results show the mechanical properties of the sintered samples prepared from blended powder are comparable to those prepared from prealloyed powder, with yield strength of 810 MPa, ultimate tensile strength (UTS) of 927 MPa, and elongation of 4.6%. The density of the as-sintered samples can reach 4.26 g/cm3 while oxygen content is ~0.3%. Based on the results, watch cases with complex shapes are successfully produced from Ti-6Al-4V blended powder. The case gives a good example of applying metal injection molding to mass production of precise Ti-6Al-4V parts with complex shapes in a cost-effective way.
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Harun W, Manam N, Kamariah M, Sharif S, Zulkifly A, Ahmad I, Miura H. A review of powdered additive manufacturing techniques for Ti-6al-4v biomedical applications. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.03.010] [Citation(s) in RCA: 80] [Impact Index Per Article: 13.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
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Fayyaz A, Muhamad N, Sulong AB. Microstructure and physical and mechanical properties of micro cemented carbide injection moulded components. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2017.12.011] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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Influence of particle-size distribution and temperature on the rheological properties of highly concentrated Inconel feedstock alloy 718. POWDER TECHNOL 2017. [DOI: 10.1016/j.powtec.2017.08.049] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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Modelling and numerical simulation of Supercritical CO2 debinding of Inconel 718 components elaborated by Metal Injection Molding. APPLIED SCIENCES-BASEL 2017. [DOI: 10.3390/app7101024] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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Dehghan-Manshadi A, Bermingham MJ, Dargusch M, StJohn D, Qian M. Metal injection moulding of titanium and titanium alloys: Challenges and recent development. POWDER TECHNOL 2017. [DOI: 10.1016/j.powtec.2017.06.053] [Citation(s) in RCA: 55] [Impact Index Per Article: 7.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
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