Flow behavior characteristic for injection process using nano-yttria stabilized zirconia for micro metal injection molding (μMIM)

Farhana Mohd Foudzi, Norhamidi Muhamad, Abu Bakar Sulong, Hafizawati Zakaria

Research output: Chapter in Book/Report/Conference proceedingConference contribution

4 Citations (Scopus)

Abstract

Micro metal injection molding (μMIM) prior to conventional plastic injection molding (PIM) has become widely demanding due to its smaller size, more complex geometric surface and time consuming on its product. Metal and ceramic in powder form of various sizes up to μm is mixed with binder system to produce products that meet the requirements. Nano size yttria stabilized zirconia (YSZ) with average particle size of 25nm, was tested both physically and mechanically for its properties before mixing and injection process using several testing such as Scanning Electron Microscopy (SEM), Energy Dispersive X-ray (EDX), pycnometer density, critical powder volume percentage (CPVP) and rheology respectively. Grain shape for YSZ particle is near spherical with the diameter range between 21.2 - 33.5nm while the CPVP shows the highest powder loading was 41.4%. Binder system of 70% palm stearin and 30% polypropylene (PP) was then mixed with YSZ at 37%, 38% and 39% by using internal mixer with roller blade type. By using CPVP of 41.4% as the guideline, mixing was done beyond the critical point until it is capable of becoming the dough mixture and was found that 43% powder loading is the highest loading it can achieved. This dough form of every mixture of powder loading was crushed to obtain pellet size as the feedstock. Rheology test was carried out for each powder loading at 180°C, 190°C and 200°C with the load increasing from 10N to 20N to determine the plastic behavior and best relationship between viscosity (Pa.s) and shear rate (1/s). Dilatant flow behavior for all the powder loadings and smooth data distribution during testing at 180°C was observed respectively. Critical parameters involving in injection process such as mold temperature (°C), melt temperature (°C), pressure (bar) and time (s) was manipulated for every powder loading to obtain the best result with no defects such as shot and flashing. Each critical parameter increased gradually as the powder loading (%) increased. Debinding and sintering process will be carried out to determine the strength and toughness by using micro hardness and micro tensile test respectively.

Original languageEnglish
Title of host publicationApplied Mechanics and Materials
Pages480-484
Number of pages5
Volume44-47
DOIs
Publication statusPublished - 2011
Event2010 International Conference on Frontiers of Manufacturing and Design Science, ICFMD2010 - Chongqing
Duration: 11 Dec 201012 Dec 2010

Publication series

NameApplied Mechanics and Materials
Volume44-47
ISSN (Print)16609336
ISSN (Electronic)16627482

Other

Other2010 International Conference on Frontiers of Manufacturing and Design Science, ICFMD2010
CityChongqing
Period11/12/1012/12/10

Fingerprint

Metal molding
Yttria stabilized zirconia
Injection molding
Powders
Rheology
Binders
Plastics molding
Testing
Microhardness
Shear deformation
Feedstocks
Toughness
Polypropylenes
Sintering

Keywords

  • Dilatant
  • Flow behavior
  • Rheology

ASJC Scopus subject areas

  • Engineering(all)

Cite this

Foudzi, F. M., Muhamad, N., Sulong, A. B., & Zakaria, H. (2011). Flow behavior characteristic for injection process using nano-yttria stabilized zirconia for micro metal injection molding (μMIM). In Applied Mechanics and Materials (Vol. 44-47, pp. 480-484). (Applied Mechanics and Materials; Vol. 44-47). https://doi.org/10.4028/www.scientific.net/AMM.44-47.480

Flow behavior characteristic for injection process using nano-yttria stabilized zirconia for micro metal injection molding (μMIM). / Foudzi, Farhana Mohd; Muhamad, Norhamidi; Sulong, Abu Bakar; Zakaria, Hafizawati.

Applied Mechanics and Materials. Vol. 44-47 2011. p. 480-484 (Applied Mechanics and Materials; Vol. 44-47).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Foudzi, FM, Muhamad, N, Sulong, AB & Zakaria, H 2011, Flow behavior characteristic for injection process using nano-yttria stabilized zirconia for micro metal injection molding (μMIM). in Applied Mechanics and Materials. vol. 44-47, Applied Mechanics and Materials, vol. 44-47, pp. 480-484, 2010 International Conference on Frontiers of Manufacturing and Design Science, ICFMD2010, Chongqing, 11/12/10. https://doi.org/10.4028/www.scientific.net/AMM.44-47.480
Foudzi, Farhana Mohd ; Muhamad, Norhamidi ; Sulong, Abu Bakar ; Zakaria, Hafizawati. / Flow behavior characteristic for injection process using nano-yttria stabilized zirconia for micro metal injection molding (μMIM). Applied Mechanics and Materials. Vol. 44-47 2011. pp. 480-484 (Applied Mechanics and Materials).
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