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Metal Injection Moulding can and improved, with the range of The present situation
today be considered as a maturing usable materials steadily growing,
manufacturing technology for small, standardisation is a continuously MIM is today a €2 billion global busi-
complex shaped metal components. ongoing process. The aim of this ness and many success stories have
A broad spectrum of materials is article is to give an overview of the been reported in terms of both the
available for MIM production and current situation in regards to MIM technical performance and economic
a number of steels, titanium and standards along with standardisation advantages of MIM components.
titanium alloys, nickel superalloys activities worldwide. Nevertheless, trust in MIM technology
and an increasing number of special
materials such as copper, cobalt-
chromium or tungsten are qualified
for MIM. The need for new materials
is primarily driven by upcoming
applications in the automotive,
aerospace and medical sectors. In
order to help designers, engineers,
manufacturers and customers to
choose one manufacturing process
over another for these new applica-
tions, it is very helpful if a reliable
basis for comparison is available.
Standardisation is an essential
process to provide such a database
of typically attainable results. Some
of the first international standards
for MIM were established several
decades ago and as technologies
are constantly being modified Fig. 1 International standardisation activities on Metal Injection Moulding
Vol. 11 No. 1 © 2017 Inovar Communications Ltd March 2017 Powder Injection Moulding International 59
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MIM standards
among component designers seems takes place from June 1-2,, 2017, in Fig. 1 gives an overview of MIM
to remain rather limited. The ques- Ludwigshafen, Germany. Additionally, standardisation activities worldwide
tions are why it is like this and how information on the capabilities of MIM over the last three decades. The
can we overcome this scepticism? is still not widely included in university first standardisation activities for
Firstly, there is a critical need to lectures for engineering students on MIM were initiated in the US by the
educate part designers at end-user manufacturing and material science Metal Powder Industries Federation
companies in general information courses. (MPIF) during the early 1990s. The
about MIM technology, since a lack Additionally, increased trust in a outcome was a separate edition
of knowledge is often discernible manufacturing technology always of MPIF Standard 35, published in
amongst this group. A number of goes hand in hand with the availability 1993, that focused on MIM materials.
regularly organised workshops in of reliable information on material In addition to the edition relating
the US, Asia and Europe address the properties and achievable tolerances. to MIM, Standard 35 includes
need to train engineers and topics Definitive standards also, of course, editions covering structural parts by
typically include an introduction protect against and eliminate conventional Powder Metallurgy, PM
to the fundamentals of the MIM misunderstandings between a self-lubricating bearings and steel
process chain, the handling of metal manufacturer and a purchaser and components made by Powder Forging.
powders, MIM design rules, quality help to support end-users in selecting In the years since, the MPIF has
control and material properties. The the most suitable material for a published further standards dedicated
next MIM workshop organised by particular product or application. to MIM that relate to MIM terminology
the European Powder Metallurgy Therefore, it is critical to be able to and specifications for testing MIM
Association (EPMA), as an example, rely on industry standards. materials.
60 Powder Injection Moulding International March 2017 © 2017 Inovar Communications Ltd Vol. 11 No. 1
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MIM standards
Vol. 11 No. 1 © 2017 Inovar Communications Ltd March 2017 Powder Injection Moulding International 61
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MIM standards
Table 2 Minimum property values for common MIM materials (according to MPIF Standard 35 and ISO 22068)
Fig. 3 The concepts of minimum property values and typical property values explained
62 Powder Injection Moulding International March 2017 © 2017 Inovar Communications Ltd Vol. 11 No. 1
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MIM standards
surface area, particle size distribu- inch-pound units and data tables in SI fewer materials, containing only data
tion, tap density), terms for each units. The first section describes the on low-alloy steels, stainless steels
process step along the process chain relevant terms which are necessary and copper.
(mixing, compounding, moulding, to understand and use MIM compo-
pre-sintering etc.) and terms for key nents. It additionally includes terms to ISO 22068
process parameters (for example, define chemical composition, density This standard does not apply to
solids loading, melt temperature, hold values, mechanical properties, structural parts manufactured by
pressure, shrink factor). corrosion resistance, soft magnetic other Powder Metallurgy routes such
Definitions for the name of a MIM properties and thermal properties. as press-and-sinter or powder forging
part at various stages of the process Section two and three are divided into technologies. It is solely dedicated
(green part, brown part, sintered subsections based on various types of to providing necessary information
part etc.) and the terms for typical
MIM part defects that occur due to
improper processing (jetting, flash, “The standardisation of materials
weld-line, sink, slumping, void,
blister, crazing etc.) as well as terms and their properties is essential in
for MIM material characteristics
(for example density, interconnected order to obtain reliable component
porosity, closed porosity) are also
covered.
performance”
common MIM materials in commer- for specifying materials in MIM
MIM materials cial use including low alloy steels components. Terms as well as test
(MIM-2200, MIM-2700, MIM-4140, and measurement specifications for
The standardisation of materials and MIM-4605), stainless steels (MIM- chemical composition, density, tensile
their properties is essential in order 316L, MIM-420, MIM-430L, MIM-440, properties, magnetic properties,
to obtain reliable component perfor- MIM-17-4PH), soft magnetic alloys hardness and corrosion resistance are
mance. To define material properties, (MIM-2200, MIM-Fe50Ni, MIM-Fe3Si, defined. The MIM material require-
the concepts of minimum property MIM-Fe50Co, MIM-430L), controlled ments for chemical composition,
values and typical property values are expansion alloys (MIM-F15) and mechanical and physical properties of
useful, as described in Fig. 3. Three copper (MIM-Cu). low-alloy steels (MIM-Fe2Ni, MIM-
standards have been published that For each MIM material, values for Fe2NiC, MIM-Fe8Ni, MIM-Fe8NiC,
give a generic overview on common chemical composition, density and MIM-4140, MIM-4340, MIM-4605,
MIM materials. An example of speci- mechanical properties are provided MIM-52100), stainless steels (MIM-
fied minimum values of mechanical with or without subsequent heat 316L, MIM-430, MIM-17-4PH), soft
properties is given in Table 2. Further treatment. If relevant for the listed magnetic alloys (MIM-Fe2Ni, MIM-
standards concentrate on require- material, physical properties such Fe3Si, MIM-Fe50Ni, MIM-Fe50Co,
ments in particular for titanium and as corrosion resistance (stainless MIM-430), titanium and Ti-6Al-4V are
its alloys, cobalt-chromium and steels), magnetic properties (soft specified with, as well as without,
nickel-based alloys. magnetic alloys), coefficient of subsequent heat treatment.
thermal expansion (controlled
MPIF Standard 35 expansion alloys and copper) and
This standard covers several aspects thermal conductivity (copper) are Titanium and titanium alloys
of Powder Metallurgy, including given. Both minimal values as well as
structural parts made by conventional typical values are listed in inch-pound Titanium and its alloys are of special
press-and-sinter technology and SI units. The standard is regularly interest for medical and aerospace
(Materials Standard for Structural reviewed and updated, with the latest applications in particular. It is
Parts), bearings and bushings made version being published in 2016. estimated that the current global
by PM (Materials Standard for PM market for titanium MIM components
Self-Lubricating Bearings), steel ASTM B883-15 is no more than 1% of total produc-
components made by Powder Forging A standard for MIM materials has tion. These are often, however, very
(Materials Standard for P/F Steel also been issued by ASTM denoted demanding high value applications
Parts) and for components made by B883-15 – Standard Specification that demand standards to be in place.
MIM (Materials Standard for Metal for Metal Injection Molded (MIM) To-date, there are several standards
Injection Molded Parts). Materials. The ASTM standard dealing specifically with surgical
The edition on MIM is divided was adapted from MPIF Standard implants. For MIM aerospace applica-
into three subsections; explanatory 35 and uses the same MPIF MIM tions, there are no specific standards
notes and definitions, data tables in nomenclature system but covers for titanium currently available.
Vol. 11 No. 1 © 2017 Inovar Communications Ltd March 2017 Powder Injection Moulding International 63
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MIM standards
ASTM F2989-13
This specification covers the chem-
ical, mechanical and metallurgical
requirements for unalloyed titanium
to be used in the manufacture of
surgical implants by MIM. Two types
of pure titanium are specified; Type 1
may have been densified beyond its
as-sintered density by post-sinter
processing whereas Type 2 has not
been densified after sintering and
therefore shows the as-sintered
density. Chemical composition is
provided with tolerance limits for
three different grades including the
oxygen, carbon, nitrogen, hydrogen
and iron content.
Minimum mechanical properties
are specified in inch-pound and SI
values including the ultimate tensile
strength, yield strength, elongation
and reduction of area for both types
(densified / not densified) and all
b c Lc Ld Lt w R1 R2 D three grades. The data take into
Shape ± 0.1 ± 0.1 ± 0.2 ± 0.2 ± 0.5 0.1 ± 0.5 ± 0.5 ± 0.1
large ø 5.82 ø 5.87 30.5 31.75 94.0 5.85 R 25 R 38 ø 7.85 account that a higher contamination
small ø 3.80 ø 3.85 30.5 27.50 85.5 3.85 R 23 R 23 ø 6.00 with oxygen leads to higher strength
but reduced elongation. The specifica-
* applicable for length Lc
tion also contains information about
requirements for microstructure,
Fig. 4 Tensile test pieces for specified MIM according to MPIF Standard 50 density and non-destructive examina-
tion.
ASTM F2885-11
This specification contains the
chemical, mechanical and metal-
lurgical requirements for Ti-6Al-4V
MIM components in surgical
implants. In accordance with ASTM
F2989-13 for pure titanium the
chemical composition for two types
of Ti-6Al-4V (densified / not densified)
are specified including tolerance
limits. It implies additional limits for
aluminium, vanadium and yttrium.
The mechanical properties are
listed for both types. In addition to
the titanium standard, information
regarding requirements on micro-
structure, density and non-destructive
examination are specified.
Cobalt-Chromium alloys
ASTM F2886-10
ASTM standard F2886-10 covers
the chemical, mechanical and
Fig. 5 Tensile test pieces specified for MIM according to ISO 2740 metallurgical requirements for MIM
64 Powder Injection Moulding International March 2017 © 2017 Inovar Communications Ltd Vol. 11 No. 1
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MIM standards
Vol. 11 No. 1 © 2017 Inovar Communications Ltd March 2017 Powder Injection Moulding International 65
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MIM standards
balance for weighing the samples, in aircraft manufacturing in the past. accomplished by material and
the purity of the employed gas, the Today, most metal aircraft parts feedstock modifications. Here, MIM
minimum number of measurements are produced by machining with a standards often just act as a general
to be accomplished and the required resulting high loss of raw material. guidance for the material selection.
precision for volume values. This puts MIM titanium in a strong Although missing standards
position to expand in the aerospace are probably not a major obstacle
industry. There is as yet, however, for further market growth, an
Conclusion no standard that addresses the intensive discussion between
particular requirements of MIM-Ti powder and feedstock suppliers,
Although MIM is a maturing and MIM-Ti-6Al-4V aerospace MIM parts producers and their
technology, there is still a lot of components. customers in the different market
room for the improved dissemination The specifications for the testing segments should take place to
of knowledge to part designers of MIM components still lack fatigue define a common global roadmap
employed in the wide range of end- testing requirements, which are for standardisation, thereby helping
user industries that the technology especially important for a range of to increase the awareness of MIM
serves. The need to provide ferrous based and stainless steel technology in industry.
reliable data on attainable material based components for the automo-
properties in the MIM process for tive sector and titanium materials
its customers, and prospective and aerospace applications. A More information
customers, has been recognised by potential standard on fatigue testing
the MIM industry for a long time. A should specify the geometry of test The basic information for this article
number of international standards pieces especially for MIM, since was taken from published standards
and the websites listed below:
for the most common materials, neither the standard fatigue test
Authors
as well as testing methods, have specimen nor the one defined for
therefore been established. These pressed-and-sintered materials Prof. Dr.-Ing. Frank Petzoldt
standards are reworked continu- according to ISO 3928 are suitable Deputy Director
ously by some of the international for MIM.
standardisation committees. Standards offer a reliable basis Dr.-Ing. Marco Mulser
This overview shows that in for decision making in technical Project Manager
addition to the specifications for purchasing departments. Therefore
ferrous MIM materials, specifications they can help to establish MIM as Fraunhofer IFAM
have, in particular, been generated the manufacturing technology of Wiener Str. 12
for surgical implant materials and choice in the early stages of part 28359 Bremen
the medical industry. The aerospace design, making technical discussions Germany
industry is currently regarded as a between part designers and MIM www.ifam.fraunhofer.de
potentially even bigger market for part manufacturers easier.
MIM than the medical sector and It should be mentioned that
the first titanium MIM parts are in spite of existing standards,
now being produced for commercial individual agreements between MIM
aircraft. This is in large part thanks manufacturers and end-users on
to titanium’s excellent compatibility achieving better results for measure-
to Carbon Fibre Reinforced Polymers ment tolerances and/or material
(CFRP) compared to aluminium, properties compared to standard
which has been used predominantly values are daily practice and mostly
66 Powder Injection Moulding International March 2017 © 2017 Inovar Communications Ltd Vol. 11 No. 1
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