Journal of Magnetism and Magnetic Materials 226}230 (2001) 1400}1402

Anisotropic injection molding of strontium ferrite powder using

a PP/PEG binder system
S.H. Lee, W.Y. Jeung*
Metal Processing Research Center, Korea Institute of Science and Technology, P.O. Box 131, Seoul 130-650, South Korea

Abstract

In this study, new binder system for anisotropic injection molding of Sr-ferrite was developed and a process for
injection molding of Sr-ferrite was optimized. The developed binder system is composed of 30 vol% PP, 60 vol%
PEG-20 000 and 10 vol% PEG-4000. The extraction by water was applied to remove the major binder components
PEGs and the minor binder component, PP, was subsequently burned out in air. Behaviors of extraction and thermal
debinding with time and debinding atmosphere and variations of the magnetic properties with sintering temperature
were studied. The sintered magnets made by PIM process showed residual carbon content of 230 ppm and a maximum
energy product of 4.2 MGOe.  2001 Elsevier Science B.V. All rights reserved.

Keywords: Powder injection molding; Ferrite; Residual carbon; Debinding technique

Powder injection molding (PIM) is widely used for the
production of relatively complex small components with
ceramic or metal powders. The organic binders are used
to inject the powders into a closed die cavity and must be
removed without distortion and contamination of the
compact before sintering in this process. Most important
features in PIM process are binder composition and
debinding technique [1]. Binder systems have been de-
veloped with the consideration of such debinding pre-
requisites as low energy cost, short time, and the least
e!ect on the compact.
In producing magnets by PIM process, the residual
carbon, which can damage the magnetic properties, must
be minimized [2]. Solvent extraction is, therefore, be-
lieved to be a suitable debinding method, because the
greater part of the binders can be removed in the form of
original materials without any chemical reactions. There-
fore, this method reduces amount of the binder compo-
nents that can give carbon residue after subsequent
thermal debinding owing to its chemical reactions [3].
* Corresponding author. Tel.: #82-2-958-5422; fax. #82-2-
958-5409.
E-mail address: wyjeung@kistmail.kist.re.kr (W.Y. Jeung).
In this study, new binder system for anisotropic injec-
tion molding of Sr-ferrite was developed and a process
for injection molding of Sr-ferrite was optimized.
The feedstocks were prepared by mixing the Sr-ferrite
powder with PP (Polypropylene)/PEG (Polyethyleneg-
lycol) binder system. Samples were injection molded by
a simple plunger-type machine under a magnetic "eld.
Binders were progressively removed by two steps of ex-
traction and thermal debinding. Thermal debinding be-
haviors of the molded compact were studied using
thermogravimetric analyzer (TGA). After removal of
binder component, samples were sintered at various tem-
perature in an air for 1 h. Magnetic properties of the
sintered magnets were measured using a DC magnetic
hysteresis loop tracer. Residual carbon content of the
debound compacts and sintered magnets was analyzed
by infrared absorption method.
The feedstock has a powder loading of 55 vol% and
the developed binder system is composed of 30 vol% PP,
60 vol% PEG-20 000 and 10 vol% PEG-4000. Among
various PEGs, PEG-4000 and PEG-20 000 (the numbers
designate an average molecular weight) were selected as
the major binder components from the consideration of
processibilities and extraction characteristics. PEG-
20 000 was found not only to give an enough compact
strength but also to prevent binder separation in molding

0304-8853/01/$ - see front matter  2001 Elsevier Science B.V. All rights reserved.
PII: S 0 3 0 4 - 8 8 5 3 ( 0 0 ) 0 0 9 6 0 - 4
 S.H. Lee, W.Y. Jeung / Journal of Magnetism and Magnetic Materials 226}230 (2001) 1400}1402
Fig. 1. PEG extraction behavior carried out in water at 703C.
Fig. 2. TGA of the molded and extracted compacts under
various atmospheres.
owing to its moderate viscosity. Small amount of PEG-
4000 was used for lubricating and easy demolding. PP
used as the minor binder component was found to pro-
vide enough strength to maintain the compact shape at
the extraction temperature due to its high heat de#ection
temperature (about 1003C by ASTM D648) and also give
a lower residual carbon after thermal debinding than
other polymers [4].
Fig. 1 shows the behavior of PEG extraction by water
as a function of time at 703C. The suitable extraction
temperature range for this binder system was found to be
65}903C from the DSC measurements. In this temper-
ature range, PEGs form a liquid phase promising a high
extraction rate due to their high interdi!usivity with
water and PP also maintains its strength preventing
defects of the compact. At this temperature, 95% of
PEGs could be removed by water extraction in 12 h and
open-pore channels formed by an water extraction conse-
quently enables the subsequent thermal debinding .
Fig. 2 shows thermal debinding behaviors of the
molded and extracted compacts under various atmo-
spheres. Binder decomposition of the molded compact
under argon and nitrogen showed two distinct steps of
weight loss. The "rst stage, between 300 and 4003C,
1401
Table 1
E!ect of thermal debinding atmospheres on residual carbon
content (ppm)
Air Argon Nitrogen
Debound sample 1400 5700 5800
Sintered magnet 230 250 *
Fig. 3. Variations of magnetic properties with sintering temper-
ature.
originated from the decomposition of the most binders.
The second stage, between 400 and 4503C, originated
from the broad decomposition range of PEG-20 000.
Binder decomposition of the extracted compacts under
air, however, showed a reduced decomposition range
between 150 and 2003C.
Table 1 shows the e!ect of debinding and sintering
atmosphere on residual carbon content. The residual
carbon content after thermal debinding under air is
about four times lower than those under nitrogen and
argon atmosphere. This is because the air atmosphere
gives an oxidative debinding condition by reaction with
the free radicals generated by thermal energy. Therefore,
air may be the proper thermal debinding atmosphere for
removal of developed binder system.
The debound samples were sintered at various temper-
atures and the magnetic properties of sintered magnets
are shown in Fig. 3. Remanence increased to a certain
extent with the increase of sintering temperature. Co-
ercivity gradually decreased with the increase of sintering
temperature and showed a sharp drop caused by an
exaggerated crystal growth at 13003C. The examined
temperature range is regarded to be beyond a peak of
coercivity. The magnet sintered at 12603C showed a re-
manence of 4.13 kG, a coercivity of 3.3 kOe, and a max-
imum energy product of 4.2 MGOe.
In conclusion, new binder system for anisotropic injec-
tion molding of Sr-ferrite was developed and a process
for injection molding of Sr-ferrite was optimized. By the
1402 S.H. Lee, W.Y. Jeung / Journal of Magnetism and Magnetic Materials 226}230 (2001) 1400}1402

combination of water extraction and thermal decomposi-
tion, it was possible to reduce signi"cantly the residual
carbon content. The sintered magnet made by PIM pro-
cess showed a maximum energy product of 4.2 MGOe.
The present work proved that PIM is a competitive
process for fabrication of ferrite magnetic products.
[2] H. Lee, W. Lee, W.Y. Jeung, T.J. Moon, Powder Metall. 41
(1998) 185.
[3] Petzoldt, H. Eifert, T. Hartwig, G. Veltl, Proceedings of the
Advances in Powder Metallurgy and Particular Materials,
MPIF, Princeton, NJ, 1995, p. 6.
[4] H. Lee, J.W. Choi, W.Y. Jeung, T.J. Moon, Powder Metall.
42 (1998) 41.

References

[1] R.M. German, Powder Injection Molding, MPIF, Prin-

ceton, NJ, 1990, p. 99.