In recent years, MIM is no longer a mysterious process due to the extensive use of the MIM process for cell phone parts such as cartridges and keys.
Product engineers in many other industries have also begun to learn about this unique MIM process. According to the previous Harber-mim information, I reorganized some common problems of MIM for you, of course, these questions are designed for the first time to understand the process of MIM students. Teachers will just ignore it.
1. What is the MIM process
2. How does MIM work? (Principle)
3. Is the metal melted during the molding process?
4. how is the MIM process different from a conventional PM process?
5. Does the part shrink when the adhesive is removed?
6. What happens to the density and strength of a MIM part?
7. why use the MIM process?
8. what materials can be used?
9. What is the best way to realize the benefits of MIM?
10. What is the typical lead time for the MIM process?
11. what is the average annual production volume?
12. are there guidelines for defining complexity?
13. Are there limitations?
14. what tolerances will be achieved?
15. what equipment is used in the process?
16. can MIM be heat-treated or gold-plated?
1. What is MIM technology?
The full name of MIM is Metal Injection Moulding. It is a manufacturing technology that combines plastic injection molding and traditional powder metallurgy.
2. How does MIM work?
Fine metal powders are bonded with thermoplastics and adhesives to make a raw material, which is actually plastic granules containing metal powders and adhesives. Then, through the familiar process of injection molding, a blank is formed for the desired product. Then it is processed to remove the binder component (called degreasing), and finally the degreased product is heated and sintered in a controlled high-temperature environment to obtain a dense metal part.
3. Is the metal melted during the molding process?
No, only the binder is melted so that the powder can flow like a plastic material. Cooling the binder is what gives the parts their strength. The parts are then degreased and sintered to remove the binder and achieve a very high density and strength for their mechanical properties.
4. How is MIM different from the conventional PM process?
Conventional PM uses unidirectional high pressure to press a rough metal powder into a fixed position to create moderately complex devices. In particular, there is no further improvement in density during the sintering process. This method produces density values in the 80-90% range, which limits the physical properties that make it an alloy. The elasticity of MIM allows the manufacture of complex products without limitations. Fine metal powders combined with high temperature sintering allow MIM to produce final products with high densities. This allows MIM products to have similar properties to precision materials.
5. Will the part shrink during the adhesive removal process?
No, the volume of the part does not change during the degreasing process. However, parts may deform up to 20% during sintering.
6. What happens to the density and strength of the MIM part?
Typical MIM densities are theoretically higher than 96%. The exact density characteristics depend on the choice of alloy, but in any case it is close to that of a precision material.
7. Why use MIM?
MIM has advantages in the manufacture of fine, highly complex parts that are difficult or cost prohibitive to produce using traditional machining or casting techniques. For more information, see the article: Guidelines for selecting a MIM process.
8. What materials can be used for production?
Almost all metal alloys can be used in the MIM process, and within the range of materials commonly used for MIM, typical alloys include high-strength steels, nickel-added stainless steels, and superalloys. Other materials processed include refractory alloys, titanium and copper alloys, and low melting point alloys including brass, bronze, and zinc-aluminum, but they are not economical to use in the MIM process.
9 What is the best way to realize the benefits of MIM?
The best way to realize the benefits of MIM is to apply MIM technology in the design phase early in the product production cycle.
10 Delivery cycle?
Typical lead times for machining and sample submission are 4-6 weeks. However, shorter lead times are possible depending on specific engineering requirements.
11. What is the average annual production volume?
Typically, the average annual production volume of a typical product should exceed 20K. 12.
12. Are there guidelines for defining complexity?
There is no right or wrong here. According to the thumb rule, if a drawing has more than 20 dimensions, it fits into a good MIM part.
13. Are there limitations?
Like any other technology, MIM technology has limitations. The maximum weight of the product is limited to 240 grams (economically, the weight is generally limited to no more than 50 grams). Certain geometric characteristics can also be problematic (ultra-thick or ultra-thin sections). The progress of the process in the last few years has led to breakthroughs in the maximum weight of mim products.
14. What tolerances will be achieved?
Typical MIM tolerances are 0.3% to 0.5%. However, tolerances are highly dependent on the geometric properties of the product. Exceeding MIM technical tolerances can be achieved by machining.
15. What equipment is used in the process?
The following equipment is used in the MIM process: MIM mixing & pelletizing equipment, MIM injection molding equipment, MIM degreasing equipment, MIM sintering equipment, MIM post-processing equipment.
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