An Introduction to PIM

Ceramic and Metal Injection Molding

4100 Griswold Road • Port Huron, MI 48060 • Phone: 1-810-982-9720 • Fax: 1-810-982-2382 • E-mail: mward@brittmfg.com

ContentsBritt Mfg Co…a brief overview Page 1

PIM History Page 2

Steps in the PIM process Page 3

Applications Page 4

PIM Technology – Manufacturing Process Comparison Page 5

Molding – overview Page 6

Post Molding Page 7

Debind Page 8

Debinding Mechanism Pages 9 & 10

Sintering Pages 11 & 12

Post sintering Page 13

Advantages Page 14

PIM competes Page 15

Feasibility Page 16

Part Design Page 17

Britt Mfg Co standard materials lists Pages 18 & 19

Page 1

BRITT MANUFACTURING

A RESPONSE ORIENTED MANAGED COMPANY

VISION STATEMENT

Britt is a committed World Class Supplier of quality powder injection molded products exceeding ourcustomer’s expectations.

YEARS OF OEM SUPPLY INDUSTRY SERVICE

Britt Manufacturing Corporation is an injection molding and assembly division retained from Mark Ward’ssale of Pacer Engineered Products Corporation. Britt currently has individuals on staff possessing morethan 25 years of PIM experience and 80 years of business ownership, management, manufacturing andmarketing leadership experience.

MANAGEMENT / LEADERSHIP

Britt utilizes production work teams, committee meetings and training sessions to allow Britt employee’s toparticipate in continuous improvement of job function and provide optimum input for management’sdirection.

ISO 9 0 0 1 :2 0 0 0

Certifica tion Audit 2004

PIM HISTORY

Manufacturers of the 21st century are requiring stronger, yet lighter and more durablecomponents that cost less. Fortunately, parts manufacturers are no longer forced tochoose between the production limitations of metal die casting and the materiallimitations of plastic injection molding.

The last decade has seen the development of a new manufacturing process for metal andceramic parts. This process, known as Powdered Injection Molding “PIM” or CeramicInjection Molding “CIM”, are ideal for parts requiring complex geometry, which aregenerally difficult to cast and costly to machine using traditional manufacturing methods.

State-of-the-art equipment and technical expertise have made Britt ManufacturingCompany a leader in the Powdered Injection Molding field. Using this process, we caneliminate many of the design restrictions of conventional machining or castingtechniques. Significant component weight reductions are possible, and multiplecomponents can be redesigned and manufactured as a single part, simplifying assembly.

At Britt, we understand the exciting possibilities Powdered Injection Molding presents toits customers in the aerospace, appliance, automotive, dental, electronics, medical,telecommunications, and tool industries. We welcome the opportunity to demonstrateour expertise on your next project.

Page 2

POWDER INJECTION MOLDING

POLYMER BINDERPOWDERED METAL

SINTERING OVENFINISHED PART

DEBINDING PROCESSBROWN BODY

INJECTION MOLDINGGREEN BODY

FEEDSTOCK

Page 3

APPLICATIONS

Medical Automotive Aerospace

Business Machines Gears Military

Cutting Tools Pumps Lawn & Garden

Hand Tools Power Tools Laboratory

Vending Machines Bearings Recreational

Small Machinery Jewelry Cutlery

Farm Machinery Wear Parts Plumbing

Home Appliances Connectors Electronics

Page 4

MOLDING

PIM technology is a union of thermoplastic injection molding and conventional powder metallurgy.Polymer binders mixed with fine metal or ceramic powders are injected into molds similar to those used for plastic injection molding.Slides, cores and other common tools used in conventional injection molding are able to produce more complex features thanconventional machining or casting.

Injection molding accurately duplicates mold surfaces. This results in parts having as sintered surface finishes near <32 RMS (microinches). In addition, high resolution features such as raised or subsurface lettering and logos are easily molded. Internal or externalthreads and knurled features, costly machined features, are essentially free with injection molding.

PIM uses many of the same design principles applied in molding plastic parts. Molds for injection molding have differentcharacteristics than conventional investment cast molds or dies. Injection molding uses two mold halves to form the part. Material isforced into the mold cavity through openings called gates. Once the parts cool and harden, the mold opens and the parts are ejected.Parts in the molded stage are referred to as “green parts” and are approximately 20% larger than finished dimensions.

Process details:⟨ Powder sizes are fine, usually less than 20 micro-meters.⟨ Low injection pressure, generally less than 10,000 psi (69 MPa).⟨ Low molding temperature, approximately 300ϒF (149ϒC).⟨ Shrinkage, molded part to finished size, is typically 20%.⟨ Final part densities are usually 95-98% + of theoretical density.

POST MOLDING

Molded products are referred to as “Green Parts”. Parts may be machined or other secondaries may be performed adding features in the green state. If possible, machining is easier in the green state.

Green Part before secondary (Milling) Green Part after Milling (Snap Ring Groove)

Page 7

DEBIND

Debinding is the removal of binders mixed with the metal or ceramic powders, which takes place after molding.Britt capabilities include chemical (catalytic), solvent and water debind system. The debind method is determined by thematerial to be processed, required physical properties, metallurgical requirements and chemical composition.At Britt Manufacturing we are able to utilize three debinding systems, catalytic, solvent and water. Debound parts arereferred to as “Brown Parts”.

Catalytic Debind Oven

Page 8

ChemicallyRemoved, dissolved or decomposed binder

DEBINDING MECHANISM

Debindingchemical or solvent

Binder

Metal orCeramic Powder

Page 9

DEBINDING MECHANISM

GreenPart

10 mm

10 mm

30 min

60 min 90 min

120 min 150 min

Dissolved or decomposed binder

Nitrogen

Debinding chemical or solvent

Page 10

SINTER

Parts are sintered with a temperature and atmosphere profile specific to the alloy being processed. Debound or “brown”parts are sintered in vacuum or continuous type furnaces. At the lower temperatures of the sintering cycle (300ϒ to 400ϒ C)the residual binder is removed. As the temperature increases, particles fuse, pore volume shrink, and grain boundaries format particle contacts. The grain size and part density depend on sintering time and temperature. The sintering temperature inMIM range from 1,200ϒC to 1,400ϒ C and for CIM they range from 1500ϒC to 1700ϒC. Part shrink 17-22% to nearly fulldensity.

⟨ Secondary machining, heat treat or surface treatments are available.

Page 11

0 0

200 200

400 400

600 600

800 800

1000 1000

1200 1200

1400 1400

1600 1600

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Temperature (c)

SINTERING316L G 64 in Hydrogen

Time (h)

Page 12

PIM POST SINTERING SECONDARY

Coining: parts designed without a flat surface required for sintering may need straightening or “coining” to correctminor shape and dimensional distortions.

Machining: grinding, milling or other machining secondary operations are applicable, if necessary.

Heat Treat: standard hardening methods are applicable

Coatings: most any coating your application requires are possible. Some of the available are: chrome plate, blackoxide etc.

Finishing: post sinter average finish 32 RMS. A better surface finish may be obtained with our in-house finishingdepartment.

Page 13

ADVANTAGES

Net Shape Forming

Integrate Several Functions Into One Part

Complex Geometry

High Production Rates

Near Properties Of Bar Stock Metal

Page 14

Page 15

PIM Competes

With Where

⟨ Screw machine parts ⟨ Part failure is a problem due to material failure

⟨ Investment casting (higher labor cost and design limits)

⟨ Volume in excess of 30M parts/year⟨ Minimum bore diameter < 2mm⟨ Wall thickness < 2mm⟨ Surface roughness < 5um

⟨ Powdered metal or “Press and Sinter”(design limits)

⟨ Secondary machining becomes excessive⟨ Two or more parts need to be joined⟨ Internal or external threads are required⟨ Part failure due to lack of density⟨ Design requires parts with high aspect ratios

⟨ Machining(quantities, labor & machining costs)

⟨ Quantities exceed 30,000 parts/year on simple partsand 20,000 parts on complex parts

⟨ Complex part geometry requires excessive machining

PIM competes where the design requires the flexibility of plastic injection molding and the mechanical and physicalproperties near that of bar stock materials.

FEASIBILITY

Consideration for a good PIM or CIM candidate

Component should be:

⟨ 150 grams or less in weight (typical average 50 grams or less)

⟨ Reasonably complex in design (combine components to be produced into one piece, for increased cost savings)

⟨ Maximum wall thickness .5” (12.7mm)

⟨ Minimum wall thickness .005” (.13mm)

⟨ Tolerance Range Typical Best

- angular +/- 2 deg +/- .5 deg

- dimensional +/- .3 % +/- .001” (.0254mm)

Page 16

POWDER INJECTION MOLDING PART DESIGN

PIM Part Design principals are similar to Plastic Molded Products.

⟨ Draft angles, aiding in ease of part release from mold

⟨ Uniform wall thickness is best

⟨ Gradual wall thickness transition where wall thickness must vary

⟨ Thick cross section should be cored obtaining lower production cost and assist in dimensional control

⟨ Radius corners

Additional requirements for PIM are:

⟨ Flat surface on component preventing sagging or slumping during sintering, custom trays with grooves or holes to allow for proper support areoptional.

⟨ MIM Tolerance Range.

Feature Typical Best

Angle +/- 2 deg +/- .5 deg.

Dimension +/- .3% +/- .001” (.0254mm)

Tighter tolerance is possible with secondary operation.

⟨ The flexibility of PIM component features may include: cross holes, angles, irregular shapes, undercuts, splines, gears and in some casesthreads

⟨ Gate location is critical for proper mold fill, but similar to ejector pin and mold parting lines, leave witness area on part surfaces. The locationof the molded imperfections may interfere with function as well as cosmetics. It may be to a designer’s advantage to work with us early in thedesign stage to optimize your part design for PIM.

Page 17

Standard Materials AvailableAlloy/AISI UNS * Yield St Ultim Tens Elongation Hardness Density Description

Low alloy steels

FN02 250 Mpa 500 Mpa 3% 90-110hv10 7.5 As sintered (Fe2Ni)

1447 Mpa 1655 Mpa 3% 340hv10 (55HRC) Heat Treated

FN08 400 Mpa 700 Mpa 3% 150-280hv10 7.5 As sintered (Fe8Ni)

1100 Mpa 1350 Mpa 1% 400hv10 (41HRC) Heat Treated

8620 G86200 400 Mpa 650 Mpa 3-8% 190-230hv10 7.4 As sintered

650hv10 (58HRC) Heat Treated800hv10 (64HRC) Carbonitrided

42 CrMo4 / 4140 G41400 400 Mpa 650 Mpa 3-10% 130-230hv10 7.4 As sintered (DIN 1.7225)

1250 Mpa 1450 Mpa 2% 450hv10 (45HRC) Heat Treated

600hv10 (55HRC)Surface hardness by hardening

and Nitriding

100Cr6 G52986 500 Mpa 900 Mpa 5% 230-290hv10 7.4 As sintered (DIN 1.3505, E52100)700hv10 (60HRC) Heat Treated

FeSi 7.45 Soft Magnetic Material

Alloy/AISI UNS * Yield St Ultim Tens Elongation Hardness Density Description

Stainless Steels316L S31603 180 Mpa 510 Mpa 50% 120hv10 7.85 Austenitic S.S. - nonmagnatizable

430 S43000 220 Mpa 400 Mpa 30% 125hv10 7.55 Ferritic S.S. - ferromagnetic

420 S42000 7.55 Martensitic S.S. - ferromagnetic

17-4PH S17400 550 Mpa 950 Mpa 6% 320hv10 (32HRC) 7.65Precipitation Hardening S.S.-

ferromagnetic

950 Mpa 1100 Mpa 8% 370hv10 (38HRC) Solution treated & Aged

P.A.N.A.C.E.A. 690 Mpa 1090 Mpa 35% 120hv10 Nickel free, not magnatizable

Alloy/AISI UNS * Yield St Ultim Tens Elongation Hardness Density DescriptionTool Steels

M2 8.1 SC 6-5 2-Wear Resistant Tool Steel

Bend StrengthFracture

ToughnessHardness Density

Ceramics

TZP-A600-800 Mpa

(as fired)8.2 Mpa m 1200 HV 6.08

Zirconium oxide with 5% ofytrium oxide

AO-H300-400 Mpa

(as fired)4.2 Mpa m 1800 HV 3.84 Aluminum oxide 96%

Standard Magnetic Metal Alloys

Alloy / AISI DensityHardness

HV10

ElectricalResistivity

(u Ohm cm)

CoerciveForce H2

(A/m)

Induction Bat 4

KA (T)

MaximumPolarization

Jmax(T)

At anapplied

MagneticField H of

(KA/m)

MaximumPermeability

umax

H(umax)(kA/m)

RemanenzBr(T)

Fe 7.8 54 HVO.5 10 29 1.64 1.66 5 14236 0.045 1.24

FN02 7.7390-110

80 HVO.3101 1.63 1.64 4.5 3391 0.16 0.95

FeSi3 7.59 140-160 HVO.3 40 90 1.48 1.50 5 1.09

430 7.68210-230HVO.5

60 73 1.30 1.34 5 3000 0.104 0.64

FN50 >7.9100

100-108 HVO.345 8 1.46 1.46 4.5 31500 0.018 0.99

PerformanceCoercive

ForceMaximum

PermeabilityInduction B4 Resistivity

CorrosionResistance

Hardness

Highest Fn02 FN540 F.S. 430A 430 430FeSi3 F.S. FN02 FN50 FN50 FeSi3

To 430 FeSi3 FeSi3 FeSi3 FN50F.S. FN02 430 FN02 FN02

Lowest FN50 430 FN50 F.S. FN02, FeSi3, F.S. F.e.

* Nearest UNS specification

Britt Manufacturing also has other custom alloys available upon request.All information is provided for REFERENCE ONLY - individual results may vary.