14 - 18 October 2018

Bilbao, Spain

Quality and Tolerances of MIM components

Session Chairs

Georg Breitenmoser

Frank Petzoldt

Mr Georg Breitenmoser (Parmaco Metal Injection Moulding AG, Switzerland)
Prof Frank Petzoldt (Fraunhofer IFAM, Germany)

Introduction

When evaluating the suitability of a given MIM component design some of the first questions that arise are whether the MIM process is capable to meet the tolerances and the visual requirement. Although there are general guidelines concerning the dimensional accuracy of MIM components the actual dimensional stability is not easily predictable because it depends on many factors such as geometry of the part, selected material and process parameters.

The objective of this SIS on quality and tolerances of MIM components is to highlight and understand the capability of the MIM process in terms of dimensional accuracy and visual quality, first by giving an overview on the many parameters of the MIM process and their influence on the dimensional scatter and then by looking at some case studies which give examples of what is possible in MIM mass production.

Presentations

Factors that Influence Dimensional Scatter of MIM components and their Implication on the Process Capability

Dipl.-Ing Martin Bräker (Parmaco Metal Injection Molding AG, Switzerland)

To reach the process capability requirements of customers mainly out of the automotive and the medical industry a deep knowledge of all the factors that influence the dimensional scatter of MIM components is needed. With the information gathered by in process control the most important factors which influence the dimensional scatter are identified. In a simplified view dimensional variation of MIM parts can be attributed to raw materials part design mould design and the MIM process steps each of which can be described by many individual parameters. The influence of the MIM producer on the scatter of the raw material parameters is limited. The part and mould design can be influenced by the MIM producer to some extent at the beginning of a project.

Case Studies of High Volume Production with a Special Look on Dimensional Process Capability

Dr Wolfgang Schütz (GKN, Germany)

Reliability in quality and time of delivery are essential to get success in a high volume mass production of MIM parts. Also the increasing acceptance by the automotive industry for the MIM technology allows producing these high volumes. The presentation focuses on selected examples to demonstrate the process stability in an actual state- of-the- art mass production MIM environment. It will also be demonstrated how to work with customer requirements to push the limits of the technology and to meet finally the demands of the market.

Case Studies of 'Cosmetic' MIM Components with a Special Look on Visual Quality Aspects

Dr Jean Claude Bihr (Alliance MIM, France)

The presentation will try to exhibit some specific points about cosmetic parts made in MIM.Cosmetic parts have on top of the characteristics of all other parts three uncommon features: the surface roughness the respect of the details and if polished the microstructure. The presentation will describe how the MIM process can be seen as a signal-like technology and presents some techniques to create a qualitative signal and organize a process flow that will destroy as little as possible the quality of the signal. The accuracy and the definition of the signal come from the feedstock and the association of the tool and the injection parameters. The signal being the green part once it is shaped nothing can make it better in term of cosmetic. So once the green part is out of the tool the process needs to be designed in a way that distortion and modification are affecting


Functional Materials: Soft and Hard Magnetic Materials

Session Chairs

Georg Breitenmoser

Frank Petzoldt

Mr Georg Breitenmoser (Parmaco Metal Injection Moulding AG, Switzerland)
Prof Frank Petzoldt (Fraunhofer IFAM, Germany)

Introduction

Electromobility and energy-efficiency are 'hot topics' that open up new options and challenges for PM production. This Special Interest Seminar focuses on MIM for hard and soft magnetic materials, their properties and applications.

Presentations

MIM for Soft Magnetic Applications – Chances and Challenges

Dr Andreas Schoppa (PMG Füssen GmbH, Germany)

The use of MIM for soft magnetic components offers a variability of shapes that is required for a three-dimensional conduction of magnetic flux. MIM can be applied for sintered parts as well as for SMC. The presentation shows how to influence magnetic properties by the variation of some relevant process parameters.

MIM of Magnetocaloric Materials- Enabling Magnetic Cooling and Heat Pump Technologies

Dipl.-Ing. Sandra Wieland (Fraunhofer IFAM, Germany)

Magnetocaloric Materials (MCM) absorb heat in a magnetizing process or emit it during a demagnetizing process. This effect is employed in magnetic cooling devices and heat pumps which have the potential to be 30-50 % more energy efficient than conventional compressor systems and avoid the use of common environmentally harmful refrigerants. One of the challenges for the introduction of magnetic cooling devices to the market is the shaping of the MCM. Metal Injection Moulding (MIM) or Metal Powder Extrusion do not only have the potential to meet the geometrical requirements of the application but are efficient production methods capable of high volume series production as well. Based on some general aspects regarding magnetocaloric materials and systems the presentation will explain the market potential but also the technical challenges for MIM of MCM.

Production of Nd-Fe-B-Magnets by Metal Injection Molding

Dr Thomas Hartwig (Fraunhofer IFAM, Germany)

Sintered isotropic and anisotropic Nd-Fe-B magnets were manufactured by Metal Injection Molding (MIM). A commercially available alloy powder was therefore mixed with a multi-component binder system and shaped by MIM into cubes of 10x10x10 mm3. Anisotropic samples were produced by applying a magnetic field during molding. Afterwards the samples underwent a two-step debinding process and were sintered under various conditions. The magnetic properties and the texture degree expressed by the alignment factor were investigated by analyzing the demagnetization curves of magnetized samples. Also the effect of Dysprosium compounds on the magnetic properties was investigated. The feedstock was therefore mixed with various amounts of Dysprosium compounds shaped sintered and characterized. It was found that the MIM is suitable to produce isotropic and anisotropic Nd-Fe-B magnets with high densities up to 98%. The magnetic properties can be manipulated by the amount and type of the dysprosium compound.

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