On the possibilities of merging additive manufacturing and powder injection molding in the production of metal parts

Martin Novák, B. Hausnerova, V. Pata, Daniel Sanétrník
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Abstract

Purpose This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS). Design/methodology/approach PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools. Findings Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route. Originality/value This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.
增材制造与粉末注射成型技术在金属零件生产中的融合可能性
目的 本研究旨在加强增材制造(AM)技术与粉末注射成型(PIM)技术的融合。这样,原型可通过三维打印成型,并利用 PIM 实现批量生产。因此,研究了使用粉末/聚合物粘合剂原料(材料挤压(MEX)和 PIM)生产的零件的表面特性和机械性能,并与基于直接金属激光烧结(DMLS)的粉末制造进行了比较。在相关温度下获得的流变学数据用于设置注塑成型的工艺参数。测定了 PIM 烧结部件的拉伸强度、屈服强度和断裂应变,并与使用 MEX 和 DMLS 生产的部件进行了比较。通过三维扫描仪对表面特性进行了评估,并使用先进的统计工具进行了分析。研究结果对表面特性的先进统计分析显示,PIM 和 MEX 所制造的表面非常接近。拉伸强度和屈服强度以及断裂应变表明,DMLS 提供的烧结样品具有最高的强度和延展性;然而,使用环保原料制造的 PIM 零件可能会成功地与这种制造方法竞争。文献调查显示,迄今为止,还没有任何研究利用先进的统计工具对固定零件形状和尺寸的 AM 和 PIM 技术进行系统比较,以得出所调查的加工路线的接近性。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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