The metal injection molding process allows the manufacturing of small and very complex metallic components. Metal injection molding processing combines the shaping capability of polymer injection moulding with the large material variety of metals. This paper discusses in detail the development of a numerical model capable of simulating structural evolution and macroscopic deformation during sintering of complex micro-gear compacts. A sintering model based on elastic–viscoplastic constitutive equations was proposed, and the corresponding parameters such as sintering stress, bulk and shearing viscosities were identified from dilatometer experimental data. The constitutive model was then implemented into finite element software in order to perform the simulation of the sintering process. The numerical predictions of shrinkages and densities were compared with experimental measurements, and it is shown that the results numerically simulated by finite element agree well with those experimentally observed. The experimental data were obtained from sintering of stainless steel powders.

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Numerical simulation and experimental analysis of solid-state sintering response of 316 L stainless steel micro-parts manufactured by metal injection molding

This study proves that initial density gradients have lasting detrimental effects on final dimensional tolerances. X-ray computed tomography has been used to quantify changes in density following sintering; associated dimensional changes have been monitored using a laser micrometer. Nonuniformities present in the green state are still present at an overall relative density of ∼73%; in fact, these nonuniformities are exaggerated. Major losses of dimensional tolerance are triggered by the initial density gradients.

Density Gradients and Sintered Dimensional Tolerance in Compacts Formed from Spray-Dried Alumina

For the past 2 years, interest in manufacturing technologies based on micro-fluidic systems has been continuously increasing. Today, micro-fluidic systems are used in numerous biomedical and pharmaceutical applications. Micro-fluidics cannot be thought about separately without advances in micro- and nano-fabrication. Investigations based on experiments, finite element modelling and simulations of powder hot embossing process (PHE) were performed to optimise the sintering step and processing parameters of micro-fluidic components. The model pertaining to thermo-elasto-viscoplastic behaviour was identified for 316L stainless steel powders. In this regard, different material properties such as sintering stress, bulk, and shearing viscosities were identified by inverse analysis from present dilatometer measurements using beam-bending and free sintering tests. The identification of materials was performed for various powder volume loadings and kinetic rates for different 316L elaborated feedstock, and the parameters were obtained as functions of relative density. The initial inhomogeneity due to the PHE process has been taken into account in the sintering simulation, as it affects the final shrinkage of the sintered components. The solid-state sintering simulations were investigated for various final sintering temperatures and kinetic rates to obtain high and homogeneous relative density distributions, achieve isotropic shrinkage and optimise the sintering process parameters. The numerical simulations were realised based on the identified parameters on a 3D micro-structured specimen with an associated rectangular plate support elaborated by PHE; this allowed a comparison between the numerical predictions and the experimental results for the sintering stage. The finite element simulation results of the sintering stage with a micro-fluidic structured component at a high final temperature (1360 °C) are in excellent agreement with the results of the experiments. The comparison of the simulation and experimental results validated the identified and implemented physical model and proposed methodologies.

Experimental analysis and numerical simulation of sintered micro-fluidic devices using powder hot embossing process

This paper describes and demonstrates the effectiveness of a finite-element procedure to predict the shape changes of “green powder compacts” during sintering processes. The approach is based on the conservation-of-mass principle and requires for its implementation (i) descriptions of the finite-element meshes of the original form (powder bed) and the green bodies when ejected from the die (thus, de-scriptions of the geometries of the compact before and after the compaction process) and (ii) the densities of the com-pacts before the compaction and after the sintering pro-cesses. Numerical shape predictions have been compared with experimental data, for all the external surfaces that are obtained from sintered, cylindrical alumina specimens. The overall predicted diametric dimensional-variation changes correlate with the corresponding measured data; both indicate a “barrel” shape. The comparisons reveal that the quantitative predictions in regard to the height and diameter range correlate closely with the measured values; the differences are <1.6% and 0.4%–0.08%, respectively. The overall predicted deviation changes of the end surfaces of the sintered compacts correlate with the corresponding measured data; both indicate a “concave” shape, with ref-erence to the horizontal plane, as viewed from the compac-tion direction. The quantitative shape comparisons for the top and bottom surfaces are <18.9% and <65.84%, respec-tively. The qualitative predictions at the top and bottom surfaces are considered to be in good agreement, for most practical purposes.

A Finite‐Element Approach for the Shape Prediction of Ceramic Compacts during Sintering

Finite element sintering analysis of metal injection molded copper brown body using thermo-physical data and kinetics

A geometrical finite element model of the sintering process of advanced ceramics

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A geometrical finite element model of the sintering process of advanced ceramics