Materials processing research opportunities in powder injection molding
- Penn State Univ., University Park, PA (United States)
Materials processing is an active area with many research opportunities for advanced instrumentation, control, and modeling. Among new materials processing routes, powder injection molding (PIM) has rapidly grown from a curiosity to a viable production technique over just a few years. This manufacturing technique is applicable to all materials, and is the preferred fabrication route for many complex-shaped, high-performance components for surgical tools, computer hardware, automotive systems, consumer products, and turbine components. This presentation introduces the use of a computer controlled injection molding machine to shape powders (metal, carbide, composite, and ceramic) in a high productivity setting. After molding the organic is extracted and the powder structure is sintered to full density. Much research is needed in process modeling, control, inspection, and optimization. This presentation summarizes the basic technology and several important factors relevant to manufacturing. An important development is in minimization of molding defects via closed-loop feedback control using pressure, temperature, and optical sensors. Recent progress has occurred using in situ guided waves for ultrasonic inspection of the molded part. Neural networks are being generated to allow assessment of processing changes as required from the integrated robot, visual imaging, pressure, and ultrasonic sensors. Similar, but less refined efforts are occurring in die compaction technology. As another example, computer simulation of heat transfer is needed during sintering to understand sources of component warpage during densification. A furnace equipped with visual imaging and residual gas analysis is being used to assist in verification of such computer simulations. These tools are still in the research stage, so future integration into the manufacturing environment will bring new challenges.
- OSTI ID:
- 175095
- Report Number(s):
- CONF-950686-; TRN: 95:006111-0003
- Resource Relation:
- Conference: Joint applied mechanics and materials summer meeting, Los Angeles, CA (United States), 28-30 Jun 1995; Other Information: PBD: 1995; Related Information: Is Part Of AMD - MD `95: Summer conference; PB: 520 p.
- Country of Publication:
- United States
- Language:
- English
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