Feedstock Technology for Reactive Metal Injection Molding: Process, Design, and Application

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Feedstock Technology for Reactive Metal Injection Molding: Process, Design, and Application
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Contents
1 Reactive powder metal injection molding
	1.1 Metal injection molding—a standout manufacturing technology?
	1.2 Overview of metal injection molding
		1.2.1 Metal injection molding processes
		1.2.2 Design consideration
		1.2.3 Powders for metal injection molding
		1.2.4 Binder selection
		1.2.5 Feedstock preparation
		1.2.6 Molding operation
		1.2.7 Debinding
		1.2.8 Sintering
	1.3 Evolution of metal injection molding technology
		1.3.1 Materials development
		1.3.2 Technological advancements
		1.3.3 Current status
	1.4 Opportunities for metal injection molding of reactive metals
		1.4.1 Increasing demand for miniaturization
		1.4.2 Advantages over conventional manufacturing techniques
		1.4.3 Demand from the medical sector
		1.4.4 Materials that are hard to process
		1.4.5 Market statistics and research direction
		1.4.6 Applications
	1.5 Constraints on the reactive powders metal injection molding
	References
2 Design strategy of binder systems and feedstock chemistry
	2.1 The role of binder
	2.2 Basics of binder
		2.2.1 Binder chemistry
		2.2.2 Classifications of binder system
			2.2.2.1 Wax-based binder system
			2.2.2.2 Polyoxymethylene-based binder system
			2.2.2.3 Water-based binder system
	2.3 Feedstock chemistry and properties
		2.3.1 Feedstock flow: powder characteristics and optimal solids loading
		2.3.2 Shear sensitivity
		2.3.3 Temperature sensitivity
		2.3.4 Thermal conductivity and heat capacity
		2.3.5 Strength model
	2.4 Summary
	References
3 Binder system interactions and their effects
	3.1 Interactions between binder components
		3.1.1 Polymer blends
		3.1.2 Thermodynamics of polymer blends
			3.1.2.1 Flory–Huggins theory
			3.1.2.2 Solubility parameter approach
		3.1.3 Experimental methods
			3.1.3.1 Determination of interaction parameters for binary systems
			3.1.3.2 Glass transition temperature (Tg) measurements
			3.1.3.3 Infrared spectroscopy
			3.1.3.4 Microscopy
		3.1.4 Common binder blends
		3.1.5 Further remarks for binder blends
			3.1.5.1 Case study: complex interactions and their effects on reactive powders-MIM
	3.2 Interactions between powder and binder
		3.2.1 Role of surfactant
		3.2.2 Basic chemistry of surfactant
		3.2.3 Case study: surfactants other than stearic acid for reactive powders-MIM
	3.3 Summary
	References
4 Impurity management in reactive metals injection molding
	4.1 The importance of impurity control
	4.2 Methods of controlling impurities
		4.2.1 Selection of primary component
		4.2.2 Control of impurities and thermal debinding mechanisms
		4.2.3 Sintering and impurity control
	4.3 Points to consider for other reactive powders metal injection molding
		4.3.1 Pure Al-metal injection molding
		4.3.2 Metal injection molding of aluminum alloy 6061 with tin
		4.3.3 Metal injection molding of Mg and its alloys
	4.4 Process control
	4.5 Summary
	References
5 Potential feedstock compositions for metal injection molding of reactive metals
	5.1 Polymers that thermally degrade by depolymerization
	5.2 Minimizing oxidation in Al or Mg-MIM
		5.2.1 Attempts to address Al-MIM
	5.3 Commercial feedstocks and their properties
	5.4 Ti-MIM success stories
		5.4.1 Medical implants by Ti-MIM
		5.4.2 Smart-glasses titanium arm by MIM
	5.5 Summary
	References
6 Outlook of reactive metal injection molding
	6.1 Future trends
		6.1.1 Market opportunities
			6.1.1.1 Electronics
			6.1.1.2 Consumer decorative products
			6.1.1.3 Medical applications
		6.1.2 Patents highlighting the success of reactive powders metal injection molding
	6.2 Summary
	References
Index
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