Influence of the Injection Process on Two-Phase Separation in Stainless-Steel Metal Powder Injection Molding
A common issue encountered in metal powder injection molding is the separation of the powder and binder during the injection process, which can give rise to a number of defects. In order to investigate the phenomenon of phase separation in stainless-steel injected flat parts, a numerical simulation...
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MDPI AG
2025-01-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/15/1/38 |
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| author | Yan Li Xingjie Peng Xiang Zan Laima Luo Yucheng Wu |
| author_facet | Yan Li Xingjie Peng Xiang Zan Laima Luo Yucheng Wu |
| author_sort | Yan Li |
| collection | DOAJ |
| description | A common issue encountered in metal powder injection molding is the separation of the powder and binder during the injection process, which can give rise to a number of defects. In order to investigate the phenomenon of phase separation in stainless-steel injected flat parts, a numerical simulation methodology was employed by using the Moldex3D R14.0 finite element software to simulate the injection process. Then, the impact of injection parameters on separation was analyzed by comparing key performance indicators such as powder volumetric concentration and density. Furthermore, the extent of the separation was minimized by the optimization of process parameters. The simulation results indicate that the separation of binder and powder is most severe near the gate, where the binder percentage is the highest. The application of elevated mold temperatures, augmented injection rates and reduced injection temperatures can effectively mitigate the two-phase separation phenomenon and enhance the uniformity of powder distribution. This provides a crucial theoretical foundation and technical support for the enhancement of the quality and performance of metal powder injection products. |
| format | Article |
| id | doaj-art-ed741731abd44238bed4880a37670817 |
| institution | Kabale University |
| issn | 2075-4701 |
| language | English |
| publishDate | 2025-01-01 |
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| record_format | Article |
| series | Metals |
| spelling | doaj-art-ed741731abd44238bed4880a376708172025-01-24T13:41:29ZengMDPI AGMetals2075-47012025-01-011513810.3390/met15010038Influence of the Injection Process on Two-Phase Separation in Stainless-Steel Metal Powder Injection MoldingYan Li0Xingjie Peng1Xiang Zan2Laima Luo3Yucheng Wu4School of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, ChinaSchool of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, ChinaSchool of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, ChinaSchool of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, ChinaSchool of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, ChinaA common issue encountered in metal powder injection molding is the separation of the powder and binder during the injection process, which can give rise to a number of defects. In order to investigate the phenomenon of phase separation in stainless-steel injected flat parts, a numerical simulation methodology was employed by using the Moldex3D R14.0 finite element software to simulate the injection process. Then, the impact of injection parameters on separation was analyzed by comparing key performance indicators such as powder volumetric concentration and density. Furthermore, the extent of the separation was minimized by the optimization of process parameters. The simulation results indicate that the separation of binder and powder is most severe near the gate, where the binder percentage is the highest. The application of elevated mold temperatures, augmented injection rates and reduced injection temperatures can effectively mitigate the two-phase separation phenomenon and enhance the uniformity of powder distribution. This provides a crucial theoretical foundation and technical support for the enhancement of the quality and performance of metal powder injection products.https://www.mdpi.com/2075-4701/15/1/38metal powder injection moldingtwo-phase separationnumerical simulationprocess optimization |
| spellingShingle | Yan Li Xingjie Peng Xiang Zan Laima Luo Yucheng Wu Influence of the Injection Process on Two-Phase Separation in Stainless-Steel Metal Powder Injection Molding Metals metal powder injection molding two-phase separation numerical simulation process optimization |
| title | Influence of the Injection Process on Two-Phase Separation in Stainless-Steel Metal Powder Injection Molding |
| title_full | Influence of the Injection Process on Two-Phase Separation in Stainless-Steel Metal Powder Injection Molding |
| title_fullStr | Influence of the Injection Process on Two-Phase Separation in Stainless-Steel Metal Powder Injection Molding |
| title_full_unstemmed | Influence of the Injection Process on Two-Phase Separation in Stainless-Steel Metal Powder Injection Molding |
| title_short | Influence of the Injection Process on Two-Phase Separation in Stainless-Steel Metal Powder Injection Molding |
| title_sort | influence of the injection process on two phase separation in stainless steel metal powder injection molding |
| topic | metal powder injection molding two-phase separation numerical simulation process optimization |
| url | https://www.mdpi.com/2075-4701/15/1/38 |
| work_keys_str_mv | AT yanli influenceoftheinjectionprocessontwophaseseparationinstainlesssteelmetalpowderinjectionmolding AT xingjiepeng influenceoftheinjectionprocessontwophaseseparationinstainlesssteelmetalpowderinjectionmolding AT xiangzan influenceoftheinjectionprocessontwophaseseparationinstainlesssteelmetalpowderinjectionmolding AT laimaluo influenceoftheinjectionprocessontwophaseseparationinstainlesssteelmetalpowderinjectionmolding AT yuchengwu influenceoftheinjectionprocessontwophaseseparationinstainlesssteelmetalpowderinjectionmolding |