Micro-powder injection molding of cemented tungsten carbide: Feedstock preparation and properties

Abdolali Fayyaz, Norhamidi Muhamad, Abu Bakar Sulong, Heng Shye Yunn, Sri Yulis M Amin, Javad Rajabi

Research output: Contribution to journalArticle

4 Citations (Scopus)

Abstract

Micro-powder injection molding (μPIM) is an advanced net-shaping process for manufacturing metal, ceramic and carbide complex micro-components. The hardmetal ceramic-metal composite cemented tungsten carbide (WC-Co) is known for its high hardness, reasonable toughness, and high abrasion and wear resistance in various applications. This study focused on the characterization and evaluation of WC-Co powder as a feedstock through μPIM. A WC-10 wt.% Co powder was mixed with a paraffin wax (PW) and low density polyethylene (LDPE) binder to obtain the feedstock. The powder-binder mixture was prepared in 49-51 vol.% powder loadings to investigate the effects of the powder content on the feedstock properties. Differential scanning calorimetry and thermogravimetric analysis were conducted to determine the mixing, injection molding, and de-molding stage temperatures. The flow behaviors of the feedstock were evaluated using a capillary rheometer. Finally, the mechanical properties and density of the molded and sintered components were evaluated. This experimental work reveals that the as-received WC powder requires de-agglomeration using sufficient ball milling to achieve an acceptable level of powder loading. The green parts were successfully molded using feedstocks with 49 and 50 vol.% powder loadings. The results indicate that the WC-10 wt.% Co feedstock with a 50 vol.% powder loading provides a sufficient compromise between moldability, green density and stiffness. After debinding and sintering, the findings indicate that a micro part can be successfully fabricated through the μPIM process using the WC-10 wt.% Co feedstock.

Original languageEnglish
Pages (from-to)3605-3612
Number of pages8
JournalCeramics International
Volume41
Issue number3
DOIs
Publication statusPublished - 1 Apr 2015

Fingerprint

Tungsten carbide
Injection molding
Powders
Feedstocks
Cermets
Wear resistance
Binders
tungsten carbide
Paraffin waxes
Rheometers
Ball milling
Low density polyethylenes
Polyethylene
Molding
Toughness
Carbides
Thermogravimetric analysis
Differential scanning calorimetry
Sintering
Agglomeration

Keywords

  • Carbides
  • Composites
  • Injection molding
  • Thermal properties

ASJC Scopus subject areas

  • Ceramics and Composites
  • Process Chemistry and Technology
  • Electronic, Optical and Magnetic Materials
  • Surfaces, Coatings and Films
  • Materials Chemistry

Cite this

Micro-powder injection molding of cemented tungsten carbide : Feedstock preparation and properties. / Fayyaz, Abdolali; Muhamad, Norhamidi; Sulong, Abu Bakar; Yunn, Heng Shye; Amin, Sri Yulis M; Rajabi, Javad.

In: Ceramics International, Vol. 41, No. 3, 01.04.2015, p. 3605-3612.

Research output: Contribution to journalArticle

Fayyaz, Abdolali ; Muhamad, Norhamidi ; Sulong, Abu Bakar ; Yunn, Heng Shye ; Amin, Sri Yulis M ; Rajabi, Javad. / Micro-powder injection molding of cemented tungsten carbide : Feedstock preparation and properties. In: Ceramics International. 2015 ; Vol. 41, No. 3. pp. 3605-3612.
@article{c03d54ded89b4ade9afd6e6644409879,
title = "Micro-powder injection molding of cemented tungsten carbide: Feedstock preparation and properties",
abstract = "Micro-powder injection molding (μPIM) is an advanced net-shaping process for manufacturing metal, ceramic and carbide complex micro-components. The hardmetal ceramic-metal composite cemented tungsten carbide (WC-Co) is known for its high hardness, reasonable toughness, and high abrasion and wear resistance in various applications. This study focused on the characterization and evaluation of WC-Co powder as a feedstock through μPIM. A WC-10 wt.{\%} Co powder was mixed with a paraffin wax (PW) and low density polyethylene (LDPE) binder to obtain the feedstock. The powder-binder mixture was prepared in 49-51 vol.{\%} powder loadings to investigate the effects of the powder content on the feedstock properties. Differential scanning calorimetry and thermogravimetric analysis were conducted to determine the mixing, injection molding, and de-molding stage temperatures. The flow behaviors of the feedstock were evaluated using a capillary rheometer. Finally, the mechanical properties and density of the molded and sintered components were evaluated. This experimental work reveals that the as-received WC powder requires de-agglomeration using sufficient ball milling to achieve an acceptable level of powder loading. The green parts were successfully molded using feedstocks with 49 and 50 vol.{\%} powder loadings. The results indicate that the WC-10 wt.{\%} Co feedstock with a 50 vol.{\%} powder loading provides a sufficient compromise between moldability, green density and stiffness. After debinding and sintering, the findings indicate that a micro part can be successfully fabricated through the μPIM process using the WC-10 wt.{\%} Co feedstock.",
keywords = "Carbides, Composites, Injection molding, Thermal properties",
author = "Abdolali Fayyaz and Norhamidi Muhamad and Sulong, {Abu Bakar} and Yunn, {Heng Shye} and Amin, {Sri Yulis M} and Javad Rajabi",
year = "2015",
month = "4",
day = "1",
doi = "10.1016/j.ceramint.2014.11.022",
language = "English",
volume = "41",
pages = "3605--3612",
journal = "Ceramics International",
issn = "0272-8842",
publisher = "Elsevier Limited",
number = "3",

}

TY - JOUR

T1 - Micro-powder injection molding of cemented tungsten carbide

T2 - Feedstock preparation and properties

AU - Fayyaz, Abdolali

AU - Muhamad, Norhamidi

AU - Sulong, Abu Bakar

AU - Yunn, Heng Shye

AU - Amin, Sri Yulis M

AU - Rajabi, Javad

PY - 2015/4/1

Y1 - 2015/4/1

N2 - Micro-powder injection molding (μPIM) is an advanced net-shaping process for manufacturing metal, ceramic and carbide complex micro-components. The hardmetal ceramic-metal composite cemented tungsten carbide (WC-Co) is known for its high hardness, reasonable toughness, and high abrasion and wear resistance in various applications. This study focused on the characterization and evaluation of WC-Co powder as a feedstock through μPIM. A WC-10 wt.% Co powder was mixed with a paraffin wax (PW) and low density polyethylene (LDPE) binder to obtain the feedstock. The powder-binder mixture was prepared in 49-51 vol.% powder loadings to investigate the effects of the powder content on the feedstock properties. Differential scanning calorimetry and thermogravimetric analysis were conducted to determine the mixing, injection molding, and de-molding stage temperatures. The flow behaviors of the feedstock were evaluated using a capillary rheometer. Finally, the mechanical properties and density of the molded and sintered components were evaluated. This experimental work reveals that the as-received WC powder requires de-agglomeration using sufficient ball milling to achieve an acceptable level of powder loading. The green parts were successfully molded using feedstocks with 49 and 50 vol.% powder loadings. The results indicate that the WC-10 wt.% Co feedstock with a 50 vol.% powder loading provides a sufficient compromise between moldability, green density and stiffness. After debinding and sintering, the findings indicate that a micro part can be successfully fabricated through the μPIM process using the WC-10 wt.% Co feedstock.

AB - Micro-powder injection molding (μPIM) is an advanced net-shaping process for manufacturing metal, ceramic and carbide complex micro-components. The hardmetal ceramic-metal composite cemented tungsten carbide (WC-Co) is known for its high hardness, reasonable toughness, and high abrasion and wear resistance in various applications. This study focused on the characterization and evaluation of WC-Co powder as a feedstock through μPIM. A WC-10 wt.% Co powder was mixed with a paraffin wax (PW) and low density polyethylene (LDPE) binder to obtain the feedstock. The powder-binder mixture was prepared in 49-51 vol.% powder loadings to investigate the effects of the powder content on the feedstock properties. Differential scanning calorimetry and thermogravimetric analysis were conducted to determine the mixing, injection molding, and de-molding stage temperatures. The flow behaviors of the feedstock were evaluated using a capillary rheometer. Finally, the mechanical properties and density of the molded and sintered components were evaluated. This experimental work reveals that the as-received WC powder requires de-agglomeration using sufficient ball milling to achieve an acceptable level of powder loading. The green parts were successfully molded using feedstocks with 49 and 50 vol.% powder loadings. The results indicate that the WC-10 wt.% Co feedstock with a 50 vol.% powder loading provides a sufficient compromise between moldability, green density and stiffness. After debinding and sintering, the findings indicate that a micro part can be successfully fabricated through the μPIM process using the WC-10 wt.% Co feedstock.

KW - Carbides

KW - Composites

KW - Injection molding

KW - Thermal properties

UR - http://www.scopus.com/inward/record.url?scp=84921820844&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=84921820844&partnerID=8YFLogxK

U2 - 10.1016/j.ceramint.2014.11.022

DO - 10.1016/j.ceramint.2014.11.022

M3 - Article

AN - SCOPUS:84921820844

VL - 41

SP - 3605

EP - 3612

JO - Ceramics International

JF - Ceramics International

SN - 0272-8842

IS - 3

ER -