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GB2394724A - Making multi-component objects using metal injection moulding - Google Patents

Making multi-component objects using metal injection moulding Download PDF

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Publication number
GB2394724A
GB2394724A GB0225163A GB0225163A GB2394724A GB 2394724 A GB2394724 A GB 2394724A GB 0225163 A GB0225163 A GB 0225163A GB 0225163 A GB0225163 A GB 0225163A GB 2394724 A GB2394724 A GB 2394724A
Authority
GB
United Kingdom
Prior art keywords
blank
recess
thermoplastic
produced
metal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB0225163A
Other versions
GB0225163D0 (en
Inventor
Jean-Claude Bihr
Michel Bezin
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Alliance S A
Original Assignee
Alliance S A
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to DE10127626A priority Critical patent/DE10127626C2/en
Application filed by Alliance S A filed Critical Alliance S A
Priority to GB0225163A priority patent/GB2394724A/en
Publication of GB0225163D0 publication Critical patent/GB0225163D0/en
Publication of GB2394724A publication Critical patent/GB2394724A/en
Withdrawn legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/22Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B22F3/225Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10Processes characterised by the sequence of their steps
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00Aspects linked to processes or compositions used in powder metallurgy

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Powder Metallurgy (AREA)

Abstract

A first method (figs. 2 and 3) comprises forming a component 6 from an injection moulded mixture of metal powder and a thermoplastic or polymeric material, inserting a second component 8 into a recess 7 formed in the first and sintering. The first component 6 shrinks during sintering, with the dimensions of the recess 7 being such that the first component 6 surrounds the second non-positively. Preferably the second component 8 consists of a metal (it too may be made by metal injection moulding) which forms a diffusion zone 11 with the first component 6. In a second method a first component 6 is made by injection moulded mixture of metal powder and a Thermoplastic or polymeric material. This component 6 is placed in a mould where it is surrounded by a mixture of metal powder and a thermoplastic or polymeric material which forms a second component 8. On sintering the first component 6 shrinks more than the second whereby a positive, movable connection is formed between the two components.

Description

Process for producing constructed workpieces The invention relates to a
process for producing constructed workpieces.
A process for producing a constructed piston is known from DE 44 14 095 Al. In that case a metal with a coefficient of thermal expansion differing from the metal of the piston shaft is cast into a peripheral groove of the piston shaft to produce a piston ring carrier. This coefficient is selected such that, on solidification of the cast material, the piston ring carrier shrinks onto the piston shaft.
According to DE 199 17 175 Al a component may be produced in that a porous body is placed in a pressure die casting mould while filling the mould and, during a die casting process, is filled with a metal alloy filling the porosities of the aforementioned body.
The production of workplaces by powder metallurgy by a so-called MIM process (metal injection moulding) is also known. In this process a blank of the desired workpiece is initially produced by injection moulding a mixture of polymeric material or thermoplastic material and metal powder. The thermoplastic material is then ejected from the blank by heat treatment or thermochemical treatment, so a porous and very fragile preform of the workpiece, substantially held together by residual components of the polymeric material, is usually produced. This is then sintered, the porosities between the metal powder particles previously freed from plastics or thermoplastic material being filled and shrinkage occurring, the extent of which is predetermined by the volume of the porosities between the metal powder particles of the preform filled by the metal material.
Very diverse workplaces may be produced in this manner, for example housings for watches, gear wheels, hinge parts or other machine components.
In Patent Abstracts of Japan on JP 09194902 A the production of two elements which are movably joined together is illustrated, the two elements being produced by powder metallurgy by
the MIM process. In this process a blank of a first element is initially produced. This has a graduated recess with a comparatively narrow mouth, i.e. in the region of the mouth the diameter of the recess is smaller than in an inner region of the recess. Prior to sintering of the blank of the first element a second element which is dimensioned such that it fits into the narrow mouth of the recess is inserted into the aforementioned recess. During sintering of the first element the recess and the mouth are tapered in such a way that the second element still retains a certain amount of play inside the recess and remains movable but is somewhat overlapped by regions of the mouth and therefore is captively secured inside the recess.
MIM processes may also be used to produce a metal composite workpiece.
According to DE 100 53 199 Al a first blank made of a first material mixture is initially produced by injection moulding in a two-part mould, one mould part of which has a projection, so a cavity is produced inside the first blank during its extrusion. The mould part comprising the projection is then removed and replaced by a mould part without a projection. A second material mixture is then injected into the mould, so the cavity of the first blank is filled with the second material mixture by injection moulding. A composite blank is thus produced which has a region, consisting of a first material mixture, with a cavity filled with a second material mixture. During subsequent sintering of this composite blank a composite metal workpiece with zones made of different materials is created.
A fundamentally similar process is known from EP O 538 073 A2. In this case a first blank is produced from a first material mixture by injection moulding in a corresponding mould. This blank is placed in a further mould in which the aforementioned blank is surrounded with a further material mixture, so a composite material blank is again produced and is subsequently sintered to form a composite metal workpiece.
The aim of the present invention is accordingly to indicate new applications for MIM processes.
According to one aspect of the invention there is provided a process for producing constructed workpieces comprising a first element and a further element inserted into a recess of the first
i element, the first element being produced by injection moulding of a blank from a mixture of metal powder and thermoplastic or polymeric material, subsequent production of a fragile preform by thermal or thermochemical ejection of the thermoplastic or polymeric material from the blank and subsequent sintering and accompanying shrinkage of the preform and, prior to sintering, the further element being inserted into the recess which also shrinks during sintering, wherein the further element is heat-resistant and the dimensions of the recess are such that the first element surrounds the further element non-positively during sintering and the associated shrinkage. It has surprisingly been found that despite the pronounced fragility of the preform no cracks occur during shrinkage thereof in the course of sintering even if a nonpositive connection is to be achieved between the elements of the workpiece as a result of the shrinkage.
A particular advantage of the invention is that the production process may be carried out easily as a whole as, irrespective of subsequent thermal treatment stages, only one injection moulding process has to be carried out to produce the preform and to perform sintering.
A further advantage is that the first metal element may be connected to further elements made of virtually any materials which withstand at least the sintering temperature.
If the further element consists of metal or porous material a diffusion zone may be produced in the region of the boundary layer between the two elements during sintering of a first metal element, within which zone the materials of the two elements may penetrate more or less deeply and/or form an alloy-type composite with one another.
The two or all elements of the workpiece may optionally be produced by MIM processes.
The extent of shrinkage of the element produced by the MIM process, or of the elements produced in this way, occurring during sintering is substantially determined by the duration of sintering, the melting temperature of the metal powder, the grain form of the metal powder and the compaction of the metal powder or the porosities between the powder particles.
Another aspect of the present invention provides a process for producing constructed workplaces comprising a first element and a second element receiving this element in a recess, wherein initially a blank of the first element is produced by injection moulding from a mixture of metal powder and thermoplastic or polymeric material, this blank is subsequently placed in a further mould where it is surrounded with a mixture of metal powder and thermoplastic or polymeric material while the blank of the further element is produced, and then both blanks are simultaneously converted into preforms and subsequently sintered, wherein a material which, during sintering, shrinks to a greater extent than the material of the second element is used for the first element, and a positive, movable connection is achieved between the two elements during sintering.
A positive and movable connection of these elements may be achieved by using various shrinkage rates during production of the two or all elements to be joined together by the MIM process, although the blank of the first element is surrounded with the material of the second element during production of the blank of the second element.
The invention will now be described in detail, by way of example, with reference to the drawings, in which: Fig. 1 is a schematic diagram of the MIM process; Fig. 2 shows the connection of a first metal part produced by a MIM process by non-positive connection to a further metal part, optionally with additional formation of a diffusion zone between the two parts; Fig. 3 shows a non-positive and positive connection of a first metal part, produced by the MIM process, to a further metal part; and Fig. 4 shows a merely positive connection between two metal parts produced by the MIM process.
As is shown in illustration A of Fig. 1, during the production of a workpiece by the MIM process a mixture of metal powder and thermoplastic or polymeric material is initially introduced into an injection mould 2 using a conveying apparatus 1 designed, for example, as a screw conveyor. A blank of the desired workpiece is then produced in the mould 2 with compression and application of heat. This is shown schematically in illustration A of Fig. 1.
According to illustration B of Fig. l the material of the blank consists, on the one hand, of metal powder particles 3 and, on the other hand, of polymeric material 4 which forms a plastics matrix filling the free spaces remaining between the metal powder particles 3.
The polymeric material 4 is then ejected by (thermal or thermochemical) depolyrnerisation, adhesively acting residual components of the polymeric material maintaining a fragile bond between the metal powder particles 3 of the now formed preform of the workpiece.
During subsequent sintering, the metal powder particles 3 are deformed with increasing compression and shrinkage of the workpiece, the extent of shrinkage depending on the duration and temperature of the sintering process and the compaction and deformation of the metal powder particles 3 achieved thereby.
The shrinkage of the resultant workpiece, occurring during the MIM process, may be used during production of a constructed workpiece for connection of the parts thereof.
According to Fig. 2, a blank 6 of a first metal element with a recess 7 is initially produced by injection moulding the above-mentioned mixture of metal powder and thermoplastic or polymeric material. A further heatresistant element 8, which in the present example may consist of metal, is inserted into the recess 7 of the blank 6. The blank 6 is now converted into a preform by ejecting the polymeric or thermoplastic material, and the preform is subsequently sintered.
The shrinkage occurring in this process causes the first metal element 6 to non-positively surround the further element 8 when the recess 7 is appropriately dimensioned, a more or less large diffusion zone 11 being formed between the materials of the two elements 6 and 8 with
appropriately mutually adapted materials at the boundary layer between the two elements 6 and 8. In the example of Fig. 3, a blank of the first metal element 6 is again initially produced in the above-described manner. A further heat-resistant element 8 is again inserted into the recess 7 thereof. The element 8 is configured in such a way that either its height is smaller than the depth of the recess 7 or there is an undercut 9 at the region penetrating into the recess 7.
After the polymeric or thermoplastic material has been ejected from the blank of the first element 6, it is again sintered with corresponding shrinkage of the first element 6. With appropriate dimensioning of the recess 7 the further element is then fixed with non-positive connection and positive connection, the positive connection being brought about in that the material of the shrinking first element 6 overlaps the further element at its upper end in Fig. 3 or penetrates into the undercut 9.
In the example of Fig. 4, a blank of a first element 6 is initially produced by injection moulding a mixture of metal powder and thermoplastic or polymeric material. The blank of this element 6 is subsequently placed in a further mould and surrounded with a mixture of a further metal powder and thermoplastic or polymeric material, i.e. the blank of the first element 6 is enclosed by a blank of a second element 8. The polymeric or thermoplastic material is then simultaneously ejected from the two elements 6 and 8. Simultaneous sintering of the two elements 6 and 8 then follows, wherein the first element 6 may consist of a metal or an alloy with a slightly lower melting point than the material of the second element 8. This ensures that the first element 6 shrinks more during sintering than the further element 8 and a positive, movable connection is achieved between the two elements.
In contrast, with reversed choice of material, positive and non-positive embedding of the first element 6 in the second element 8 would be achieved.

Claims (8)

Claims
1. A process for producing constructed workpieces comprising a first element and a further element inserted into a recess of the first element, the first element being produced by injection moulding of a blank from a mixture of metal powder and thermoplastic or polymeric material, subsequent production of a fragile preform by thermal or thermochemical ejection of the thermoplastic or polymeric material from the blank and subsequent sintering and accompanying shrinkage of the preform and, prior to sintering, the further element being inserted into the recess which also shrinks during sintering, wherein the further element is heatresistant and the dimensions of the recess are such that the first element surrounds the further element non-
positively during sintering and the associated shrinkage.
2. A process according to claim 1, wherein the further element consists of a metal which, during sintering of the first metal element, forms a diffusion zone or allows a diffusion zone to be formed with the material thereof.
3. A process according to claim 1 or claim 2, wherein the further element is inserted into the recess before the preform of the first element is produced.
4. A process according to any one of claims I to 3, wherein the further element is produced by injection moulding of a blank of the further element from a mixture of metal powder and thermoplastic or polymeric material, subsequent production of a preform of the further element by ejecting the polymeric or thermoplastic material from the further element and subsequent sintering of the previously produced preform.
5. A process according to claim 4, wherein the further element has an undercut at its region penetrating into the recess or a height which is smaller than the depth of the recess and, in that, during sintering and shrinkage, material of the first element penetrates into the undercut or overlaps the further element at the upper end thereof, so that the said further element is positively and non-positively fixed.
6. A process for producing constructed workpieces comprising a first element and a second element receiving this element in a recess, wherein initially a blank of the first element is produced by injection moulding from a mixture of metal powder and thermoplastic or polymeric material, this blank is subsequently placed in a further mould where it is surrounded with a mixture of metal powder and thermoplastic or polymeric material while the blank of the further element is produced, and then both blanks are simultaneously converted into preforms and subsequently sintered, wherein a material which, during sintering, shrinks to a greater extent than the material of the second element is used for the first element, and a positive, movable connection is achieved between the two elements during sintering.
7. A process according to claim 6, wherein metals with different melting or softening temperatures are used for the two elements, the metal of the first element having a slightly lower melting point than the material of the second element.
8. A process for producing workpieces substantially as described herein with reference to the drawings.
GB0225163A 2001-06-07 2002-10-29 Making multi-component objects using metal injection moulding Withdrawn GB2394724A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
DE10127626A DE10127626C2 (en) 2001-06-07 2001-06-07 Process for manufacturing built workpieces
GB0225163A GB2394724A (en) 2001-06-07 2002-10-29 Making multi-component objects using metal injection moulding

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10127626A DE10127626C2 (en) 2001-06-07 2001-06-07 Process for manufacturing built workpieces
GB0225163A GB2394724A (en) 2001-06-07 2002-10-29 Making multi-component objects using metal injection moulding

Publications (2)

Publication Number Publication Date
GB0225163D0 GB0225163D0 (en) 2002-12-11
GB2394724A true GB2394724A (en) 2004-05-05

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GB0225163A Withdrawn GB2394724A (en) 2001-06-07 2002-10-29 Making multi-component objects using metal injection moulding

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GB (1) GB2394724A (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2233232A1 (en) * 2009-03-20 2010-09-29 Pratt & Whitney Canada Corp. Process for joining powder injection molded parts
US9970318B2 (en) 2014-06-25 2018-05-15 Pratt & Whitney Canada Corp. Shroud segment and method of manufacturing

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102004006954A1 (en) * 2004-02-12 2005-09-01 Basf Ag Process for joining inorganic moldings produced by injection molding from powder injection molding compositions with inorganic moldings produced by a process other than injection molding
DE102004041318A1 (en) * 2004-08-26 2006-04-27 Ina-Schaeffler Kg As a tilting or rocking lever trained cam follower for a valve train of an internal combustion engine
DE102006036690A1 (en) * 2006-08-05 2008-02-07 Forschungszentrum Karlsruhe Gmbh Compound and a method for producing the same
DE112019007712A5 (en) 2019-09-13 2022-05-25 Schunk Sintermetalltechnik Gmbh METHOD OF MAKING A HYBRID PART AND CORRESPONDING HYBRID PART
EP4282559B1 (en) 2022-05-25 2024-09-25 Schunk Sintermetalltechnik GmbH Method for manufacturing a hybrid component and corresponding hybrid component

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH02129307A (en) * 1988-11-10 1990-05-17 Casio Comput Co Ltd Metal powder molded products and their joining method
JPH0551609A (en) * 1991-08-27 1993-03-02 Kawasaki Steel Corp Method for producing powder-sintered body by injection molding with excellent surface properties
JPH0672773A (en) * 1992-08-25 1994-03-15 Matsushita Electric Works Ltd Production of sintered product of powder
JPH08134510A (en) * 1994-11-04 1996-05-28 Teiboo Kk Precision parts by metal or ceramic powder injection molding
JP2000309803A (en) * 1999-04-21 2000-11-07 Citizen Watch Co Ltd Manufacture of powder injection molded article

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5393484A (en) * 1991-10-18 1995-02-28 Fujitsu Limited Process for producing sintered body and magnet base
DE4430130A1 (en) * 1994-08-25 1996-02-29 Fischer Artur Werke Gmbh Process for the production of interlocking metal parts
JPH09194902A (en) * 1996-01-18 1997-07-29 Teiboo Kk Precision parts made by injection molding of metal or ceramic powder
JP3680552B2 (en) * 1998-04-23 2005-08-10 松下電工株式会社 Manufacturing method of composite material parts
DE10053199B4 (en) * 1999-10-28 2008-10-30 Denso Corp., Kariya-shi Method for producing a metal composite compact

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH02129307A (en) * 1988-11-10 1990-05-17 Casio Comput Co Ltd Metal powder molded products and their joining method
JPH0551609A (en) * 1991-08-27 1993-03-02 Kawasaki Steel Corp Method for producing powder-sintered body by injection molding with excellent surface properties
JPH0672773A (en) * 1992-08-25 1994-03-15 Matsushita Electric Works Ltd Production of sintered product of powder
JPH08134510A (en) * 1994-11-04 1996-05-28 Teiboo Kk Precision parts by metal or ceramic powder injection molding
JP2000309803A (en) * 1999-04-21 2000-11-07 Citizen Watch Co Ltd Manufacture of powder injection molded article

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2233232A1 (en) * 2009-03-20 2010-09-29 Pratt & Whitney Canada Corp. Process for joining powder injection molded parts
US10226818B2 (en) 2009-03-20 2019-03-12 Pratt & Whitney Canada Corp. Process for joining powder injection molded parts
US11383299B2 (en) 2009-03-20 2022-07-12 Pratt & Whitney Canada Corp. Process for joining powder injection molded parts
US9970318B2 (en) 2014-06-25 2018-05-15 Pratt & Whitney Canada Corp. Shroud segment and method of manufacturing

Also Published As

Publication number Publication date
DE10127626A1 (en) 2002-12-19
DE10127626C2 (en) 2003-12-04
GB0225163D0 (en) 2002-12-11

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