Rheological characteristics of injection molded titanium alloys powder

Ti-6Al-4V alloy powder was taken as raw material. 60%（mass fraction） paraffin, 35%low density polyethylene and 5%stearic acid were employed as binders to prepare injection feedstocks. Capillary rheometer was adopted to determine the rheological parameters and to analyze the rheological properties of the feedstocks at different milling time, powder loading and temperature. It is indicated through the results that the viscosity increases and the value of n decreases with the increase of milling time. The more the powder loading is, the higher the viscosity is. The empirical formula on the relationship between the viscosity and the powder loading is： ηr=η/ηb=A（1-Ф/Фmax）/^- m . The value m is calculated as 0.33. The flow activation energy Ea decreases with the increase of shear rate.

INJECTION MOLDED TUNGSTEN HEAVY ALLOY

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STRESS ANALYSIS OF INJECTION MOLDED PARTS IN POST-FILLING STAGE

The linear isothermo-viscoelastic constitutive equation is established according to the principle of viscoelastic mechanics. Given the boundary conditions of the temperature field, the linear thermo-viscoelastic constitutive equation is established acording to the analysis of the thermorheologically simple. The stress analysis model is constructed on the base of some reasonable hypotheses which consider the restraint conditions of mold and the characteristics of injection molding in the post-filling stage. The mathematical model is calculated by the finite difference method. The results can help to predict the warpage of plastic products.

Warpage prediction of the injection-molded strip-like plastic parts

For most strip-like plastic injection molded parts, whose cross section size is much smaller than their length, the traditional Hele-Shaw model and three-dimensional model do not work well in the prediction of the warpage be- cause of their special shape. A new solution was suggested in this work. The strip-like plastic part was regarded as a little-curved beam macrnscopically, and was divided into a few one-dimensional elements. On the section of each elemental node location, two-dimensional thermal finite element analysis was made to obtain the non- uniform thermal stress caused by the time difference of the solidification of the plastic melt in the mold. The stress relaxation, or equivalently, strain creep was dealt with by using a special computing model. On the bases of in-mold elastic stress, the final bending moment to the beam was obtained and the warpage was predict- ed in good a^reement with practical cases.

Influence of binder composition on the rheological behavior of injection-molded microsized SiC suspensions

The influence of four kinds of binders consisting of paraffin wax （PW）, random-polypropylene （RPP）, high-density polyethylene （HDPE）, and stearic acid （SA） on the theological behavior of injection-molded SiC feedstocks was investigated over a temperature range of 150℃ to 180℃ and a shear rate range of 4 s^-1 to 1259 s^^-1. The results showed that all the feedstocks exhibited pseudoplastic flow behavior. The wax-based binder of multipolymer components （PW-RPP-HDPE） exhibited better comprehensive rheological properties compared with the binder of monopolymer components （PW-RPP or PW-HDPE）. The addition of 5wt% SA to the binder could reduce the viscosity of the feedstock but enhance the rheological stability by improving the wettability between the binder and the SiC powder. The binder of 65wt% PW ＋ 15wt% HDPE ＋ 15wt% RPP ＋ 5wt% SA was found to be a better binder for microsized SiC injection molding.

Effects of heat treatment on the properties of powder injection molded AlN ceramics

The effects of two different heat-treatment atmospheres,nitrogen atmosphere and reducing nitrogen atmosphere with carbon,on the properties of Y2O3-doped aluminum nitride（AlN） ceramics were investigated.The AlN powder as a raw material was synthesized by self-propagating high-temperature synthesis（SHS） and compacts were fabricated by employing powder injection molding technique.The polymer-wax binder consisted of 60 wt.% paraffin wax（PW）,35 wt.% polypropylene（PP）,and 5 wt.% stearic acid（SA）.After the removal of binder,specimens were sintered at 1850°С in nitrogen atmosphere under atmospheric pressure.To improve the thermal conductivity,sintered samples were reheated.The result reveals that the heat-treatment atmosphere has significant effect on the properties and secondary phase of AlN ceramics.The thermal conductivity and density of AlN ceramics reheated in nitrogen gas are 180 W·m^-1·K^-1 and 3.28 g·cm^-3 and the secondary phase is yttrium aluminate.For the sample reheated in reducing nitrogen atmosphere with carbon,the thermal conductivity and density are 173 W·m^-1·K^-1 and 3.23 g·cm^-3,respectively,and the secondary phase is YN.

Analysis of Mechanical Properties of Injection Molded Short Glass Fibre (SGF)/Calcite/ABS Composites

Acrylonitrile-butadiene-Styrene (ABS), with and without calcium carbonate (calcite) particles,was used as the matrix for reinforcement with as-received short-glass fibres (were originallytreated by the manufacturer) and sized short-glass fibres with two amino-silane coupling agents.The calcite particle content is 0, 11.7 and 23.5 vol. pct for the matrices. The glass fiber contentis 0, 10 and 15 vol. pct. The matrix materials and corresponding composites were compoundedusing a twin screw extruder and dumbbell-shaped tensile bars were prepared with an injectionmolding process. The tensile and flexural properties as well as the unnotched and notchedCharpy impact energies of short glass fibre/calcite/ABS composites were studied in this paper.The effects of fibres, fibre surface treatments and particles on these mechanical properties ofthe composites were discussed in detail. An importarit information was obtained, which is thatthe tensile and flexural strengths of hybrid SGF/calcite/ABS composites are the same as thoseof corresponding fibre composites when the ratio of the interfacial adhesion strength betweenparticles and matrix to that between fibres and matrix is higher than certain value. otherwise theformer are lower than the latter.

Shape retention of injection molded stainless steel compacts

The effects of the binder composition, the powder loading, the thermal properties of feedstocks, and the injection molding parameters on the compact shape retention for metal injection molding 17-4PH stainless steel were investigated. The high-density polyethylene is more effective than ethylene vinyl acetate as a second component of the wax-based binder to retain compact shape due to its higher pyrolytic temperature and less heat of fusion. The compact distortion decreases with increasing the powder loading, molding pressure and molding temperature. There exists an optimal process combination including the powder loading of 68%, molding pressure of 120MPa and molding temperature of 150℃. Under this process condition, the percentage of distorted compacts is the lowest.

Rheological, mechanical and corrosive properties of injection molded 17-4PH stainless steel

The feedstock based on the binder 65%PW-30%EVA-5%SA has the best general rheological properties for the 17-4PH stainless steel powder. The 17-4PH stainless steel compacts sintered at 1 380 ℃ for 90 min have the best mechanical properties and the good microstructure with homogeneously distributed pore structure and the moderate-sized grains. Whereas the compacts sintered for 60 min and 120 min show an inadequate and an over-sintered microstructure respectively. The compacts sintered at 1380 ℃ for 90 min have the density of 7.70 g/cm^3, the strength of 1 275 MPa, the elongation of 5%, and hardness of HRC36. With the increase of sintering temperature, the density, strength and hardness increase, while the elongation decreases. The 17-4PH stainless steel has good corrosion resistance, showing an activation-passivation polarization curve. But the passivation potential range is narrow and the spot corrosion potential is low, indicating a low anti-spot corrosive properties.

Experimental Study of Shrinkage Displacements of Points on Injection Molded Parts

The existing research on shrinkage of the injection molded plastic part mainly focuses on various shrinkage ratios of the part dimensions,and the relevant experimental studies belong to mere dimension measurement after demoulding.Obviously,measuring after the plastic part is demoulded from the cavity can not offer shrinkage displacements of points on the plastic part.However,shrinkage displacements of points on an injection molded plastic part are essential for exposing the inner relation among shrinkage ratios of various dimensions of the part.So visualization of the in-mold plastic part which can indicate the location relationship between the part and the cavity is needed.In this paper,a visual injection mold was fabricated by adopting the half mold structure and light transmission manner.With the visual mold,in-mold shrinkage images of injection molded plastic parts were photographed after the plastic part stayed in the injection mold for 24 h.By means of digital image processing of the in-mold shrinkage images,the experimental data of shrinkage displacements of points on injection molded parts were researched.From the experimental data,it is found that shrinkage directions of points on an injection molded part are related with both positions of the gate and of the part centroid,and either the gate or the centroid will exert more influence on the shrinkage direction of some point which is closer.Furthermore,some point at the later filled area has more shrinkage distance than the point at the earlier filled area.Combination of shrinkage directions and shrinkage distances of points on an injection molded part determine shrinkage ratios for various dimensions of the part,and shrinkage directions are more influential to shrinkage ratios of dimensions.This experimental research of shrinkage displacements offers a unique approach to understand the shrinkage principles of injection molded parts.

EFFECT OF MELT TEMPERATURE ON THE PHASE MORPHOLOGY,THERMAL BEHAVIOR AND MECHANICAL PROPERTIES OF INJECTION-MOLDED PP/LLDPE BLENDS

The phase morphology and thermal behavior of various isotactic polypropylene （PP）/linear low density polyethylene （LLDPE） blends were investigated with aid of scanning electron microscopy （SEM） and differential scanning calorimetry （DSC）, respectively. The effect of barrel （melt） temperature on the morphology, thermal behavior and the resultant mechanical properties of the injection molded bars was the research focus, and the influence of LLDPE composition was also taken into account. It was found that the mechanical properties, especially the tensile ductility and the impact strength, were greatly affected by the processing temperature. The samples obtained at low temperatures had the highest elongation at break and impact strength, while those molded at high temperatures had the poorest toughness. Two reasons were responsible for that： first, the phase size in the samples increased with the processing temperature; second, possible orientation existed in the samples obtained at low processing temperatures.

Effect of sintering parameters on powder injection molded Ti(C, N)-based cermets

Effect of two-stage sintering parameters such as heating rate, top sintering temperature and holding time, sintering temperature and holding time at the second stage on relative density, transverse rupture strength(TRS) and microstructures of powder injection molded Ti(C, N)-based cermets were investigated, by means of Archimedes’s method, three-point bending test and micrographic analysis. The results show that the optimum sintering cycle for powder injection molded Ti(C, N)-based cermets comprises rapid heating (10℃/min) at low temperatures, slow heating (5℃/min) at intermediate temperatures, holding at the highest sintering temperature (1420℃) for a short time (10min), and holding at the second stage (1360℃) for a longer time (6h) to avoid grain coarsening, and that its TRS reaches 624MPa, and there are little pores in their microstructures.

Manufacturing of Injection-Molded NdFeB Magnet with (BH)max111 kJ · m-3

The bonded NdFeB magnets prepared by injection molding meet with the development tendency of the magnet in small volume, light weight and high performance ,and have a good prospect.In this paper, a modified nylonbased binder was developed for powder injection molding of NdFeB bonded magnets.The effects of pretreatment of NdFeB anisotropic magnetic powder produced with HDDR processing on the anti-oxidation behaviors of powder and the final magnetic properties of the molded bonded magnets were studied.The optimal powder loading of 65 vol% was achieved with the modified binder.It was found that the properties of the bonded magnets were mainly affected by the powder surface pretreatment and the intensity of the applied alignment magnetic field during injection molding for a certain powder.Bonded magnets with remanence of 0.820 T, intrinsic coercivity of 1140.3 kA· m-1 and maximum energy product of 111 kJ · m-3 were produced with the optimal processing.

Effect of Molecular Weight and Molecular Distribution on Skin Structure and Shear Strength Distribution near the Surface of Thin-Wall Injection Molded Polypropylene

In this study, the relationship between skin structure and shear strength distribution of thin-wall injection molded polypropylene (PP) molded at different molecular weight and molecular distribution was investigated. Skin-core structure, cross-sectional morphology, crystallinity, crystal orientation, crystal morphology and molecular orientation were evaluated by using polarized optical microscope, differential scanning calorimeter, X-ray spectroscopic analyzer and laser Raman spectroscopy, respectively, while the shear strength distribution was investigated using a micro cutting method called SAICAS (Surface And Interfacial Cutting Analysis System). The results indicated that the difference of molecular weight and molecular weight distribution showed own skin layer thickness. Especially, high molecular weight sample showed thicker layer of the lamellar orientation and molecular orientation than low molecular weight sample. In addition, wide molecular distribution sample showed large crystal orientation layer.

Flowing simulation of injection molded parts with micro-channel

In the micro-molding of component with a micro-sized channel, the ability for polymer melt to flowing into the micro-channel in a macro-sized part is a big challenge. The multidimensional flow behaviors are included in the injection molding the macro-component with a micro-channel. In this case, a simplified model is used to analyze the flow behaviors of the macro-sized part within a micro-channel. The flow behaviors in the macro-cavity are estimated by using the finite element and finite difference methods. The influence of the injection rate, micro-channel size, heat transfer coefficient, and mold temperature on the flowing distance is investigated based on the non-isothermal analytic method. The results show that an increase in the radius of the micro-channel and mold temperature can improve effectively the flowing distance in the micro-channel.

SPATIAL HIERARCHY AND INTERFACIAL STRUCTURE IN INJECTION-MOLDED BARS OF POLYPROPYLENE-BASED BLENDS AND COMPOSITES

The hierarchical structure and interfacial morphology of injection-molded bars of polypropylene （PP） based blends and composites have been investigated in detail from the skin to the core. For preparation of injection-molded bars with high-level orientation and good interfacial adhesion, a dynamic packing injection molding technology was applied to exert oscillatory shear on the melts during solidification stage. Depending on incorporated component, interfacial adhesion and processing conditions, various oriented structure and morphology could be obtained. First, we will elucidate the epitaxial behavior between PP and high-density polyethylene occurring in practical molded processing. Then, the shear-induced transcrystalline structure will be the main focus for PP/fiber composites. At last, various oriented clay structures have been ascertained unambiguously in PP/organoclay nanocomposites along the thickness of molded bars.

The Relationship between Bulk Property and Property Distribution in Thin-Wall Injection Molded PP at Different Molecular Weight and Molecular Weight Distribution

Thin-wall injection molded parts have been paid much attention to the lightweight saving from viewpoints of natural resources saving. In the injection molding, skin-core structure can be found in the parts. This skin-core structure affects the property of completed injection molding parts (bulk property) even if in thin-wall injection molding. However, there is a few research about the relationship between bulk property and internal property distribution in the injection molding specimen. In this study, thin-wall injection molded parts of polypropylene (PP) were prepared by 4 different molecular weight and molecular weight distribution to reveal the relationship between bulk property and property distribution. These characteristics were investigated by using tensile test, fracture toughness characterized by Essential Work of Fracture (EWF) method for bulk property and film tensile test by sliced sample for tensile property distribution. The property distribution test results revealed that the highly bulk property sample had thicker highly mechanical property layer on its surface.

Evolution of stresses in metal injection molding parts during sintering

The evolution of stresses due to inhomogeneity in metal injection molding （MIM） parts during sintering was investigated. The sintering model of porous materials during densification process was developed based on the continuum mechanics and thermal elasto-viseoplastic constitutive law. Model parameters were identified from the dilatometer sintering experiment. The real density distribution of green body was measured by X-ray computed tomography （CT）, which was regarded as the initial condition of sintering model. Numerical calculation of the above sintering model was carried out with the finite element soRware Abaqus, through the user-defined material mechanical behavior （UMAT）. The calculation results showed that shrinkages of low density regions were faster than those of high density regions during sintering, which led to internal stresses. Compressive stresses existed in high density regions and tensile stresses existed in low density regions. The densification of local regions depended on not only the initial density, but also the evolution of stresses during the sintering stage.

基于 Moldflow 的汽车中控台框架翘曲变形分析及优化

以某汽车中控台框架为研究对象,测量试模样品发现其翘曲变形量超过了装配要求。通过Moldflow软件模拟了该塑件实际的注塑过程,翘曲变形量的模拟值与实测平均值的最大误差为5.98%,发现该塑件翘曲变形的主要因素为冷却不均和收缩不均。本文在原物料中添加质量分数为25%的玻璃纤维以及优化工艺参数后,翘曲变形量的模拟值与初始方案相比降低了86.22%。试模验证表明,优化后的翘曲变形量模拟值与实测平均值的最大误差为4.35%,证明了Moldflow软件模拟分析的准确性。试模后各检测点的最大翘曲变形量降到了1.6 mm以下,较优化之前降低了80%以上,为类似大型复杂注塑件的翘曲变形分析及优化提供了思路。

基于Moldex 3D与正交试验的离心泵泵头注塑工艺优化

以商用离心泵泵头为研究对象,运用Moldex3D模流分析软件对其注塑成型过程进行了模拟。根据产品的结构特点设置了三种浇口方案,通过对注塑过程的模拟分析选出最佳方案来获得模具设计思路并预测制品成型后可能存在的质量问题。结果表明,平衡进浇方案的制品具有最好的综合性能,制品的翘曲变形量为1.588 mm,体积收缩率为2.444%。确认最佳浇口方案后,将充填时间(A)、保压时间(B)、冷却时间(C)和模具温度(D)作为实验因素,采用田口法构建五因素四水平的正交试验来获得最佳工艺参数,并使用极差和方差分析对结果进行置信度检测。以翘曲总位移结果为主要权重对象,通过极差分析确定了成型参数的最优组合为A_(1)B_(1)C_(1)D_(1),方差分析则验证了极差分析的结果置信度高于99%。相较于初始方案,制品的翘曲变形量从1.588 mm降低至1.214 mm,降低了23.6%;冷却时间降低至10 s,降低了40%。得知模流分析技术的使用让产品的质量和生产效率都得到了明显的优化,为预测塑件性能、降低生产成本、提高生产效率提供了一种可行的方式。