Achieving Complex-Shaped Stainless Steel Parts via a Facile Net-Shaping Method

Abstract

A facile method named metal compression molding (MCM) is developed using the 17-4PH stainless steel feedstock derived from powder injection molding. Complex golf-club featuring intricate surfaces, thin walls, and thick walls are fabricated via MCM. Simulation software Moldflow is used to study the flow behavior, pressure, and shear rates of feedstock at 180, 190, and 200 °C. The results show that most of the feedstock maintain their original position and a small amount of feedstock flow to fill mold cavity; viscosity decreases with increasing temperature, while stress and shear rate reach their maximum and minimum, respectively, at 190 °C. The MCM process demonstrates the ability to form the golf-club head, and samples with a smooth surface are obtained at the pressing temperature of 190 °C. The simulated stress distribution during MCM influences the density and mechanical properties of the sintered golf-clubs, higher stress correlates with better performance. High-density (97.89 ± 0.08) 17-4PH stainless steel shows excellent mechanical properties, with an ultimate tensile strength of 999.5 ± 7.0 MPa and an elongation of 14.15% ± 0.41%.