Multi-Component Parts made by Micro Ceramic Injection Moulding

Transkript

1 Multi-Component Parts made by Micro Ceramic Injection Moulding V. Piotter, E. Honza T. Mueller, K. Plewa Karlsruhe Institute of Technology (KIT) Institute for Applied Materials (IAM-WPT) Dr. V. Piotter

2 Contents - Introduction Micro Powder Injection Molding (MicroPIM) - 2-Component Micro Powder Injection Molding (2C-MicroPIM) - fixed connections - movable connections - Micro Inmould-labelling using PIM-Feedstocks - Outlook 2 Dr. V. Piotter

3 Micro Powder Injection Molding green body 3 Dr. V. Piotter

4 MicroPIM Ceramic gear wheel outer- approx. 275 µm EPMA Award 2008 to Parmaco MIM AG, CH Capillary for fine pitch bonding tip-ø=45µm, hole-ø=19µm SPT Roth Ltd., CH IT connector ZrO 2 64 via-holes octagon size 125µm Formatec Technical Ceramics bv, NL 4 Dr. V. Piotter

5 Multi-Component Parts Produced by MicroPIM Multi-Component Micro Powder Injection Molding Objectives Reduction of handling and assembly expenditure single-piece fabrication + assembly 2C-MicroPIM assembly Realization of (im-)mobile connections Functions integration by combining different materials 5 Dr. V. Piotter

6 2C-MicroPIM Opportunities Multifunctional Products with complimentary or contradictionary properties, e.g. conductive insulating hard tough magnetic non-magnetic bio-compatible mechanically strong tight porous 6 Dr. V. Piotter

7 Multifunctional Products - Ideas heating/cooling elements, electrical feedthroughs SOFC components, TEG housings and other possibilities 2-C ceramic heating element Al 2 O 3 + Al 2 O 3 /TiN square section 1 1 mm² BMBF-Project 2K-PIM Source: 7 Dr. V. Piotter

8 Multi-Component Micro Powder Injection Moulding Feedstock 1 Feedstock 2 slide open slide closed gate for 2. component gate for 2. component gate for 1. component gate for 1. component 8 Dr. V. Piotter

9 2C-MicroPIM Mobile + Immobile Connections Basic Rules Mobile Immobile Binder system n. r. compatible Powder loading inner section < outer section nearly equal Sintering temperature inner section < outer section nearly equal Thermal expansion nearly equal nearly equal 9 Dr. V. Piotter

10 2-Component PIM Combination of a magnetic steel (17-4PH, ) with a non-magnetic steel (316L, ) Fraunhofer Institute, IFAM Hard metal WCxCo with different Co-contents (16% and 6%), ARBURG Combined high temperature-resistive tungsten and tungsten-alloys for power generation, e.g. Fusion reactors, KIT 10 Dr. V. Piotter

11 Multi-Component Parts Produced by MicroPIM ZrO 2 Al 2 O 3 outer diameter (gear wheel): height (gear wheel): hub diameter: slit tolerance: shaft diameter: 2.932mm 1mm 0.65mm 0.1mm 1.65mm ZrO 2 Al 2 O 3 11 Dr. V. Piotter

12 Multi-Component Parts Produced by MicroPIM 2C-MicroPIM Mobile Connections 12 Dr. V. Piotter

13 2C-MicroPIM Mobile Connections ZrO 2 Al 2 O 3 sintered at 1460 C Sintering at low temperatures bears the risk of unsufficient densities => utilization of ultrafine powders 13 Dr. V. Piotter

14 Micro Powder Inmould-labelling (IML-MicroPIM) - combining the advantages of two shaping methods doctor blade tape casting tape feedstock EU Project No. FP7-NMP Dr. V. Piotter

15 Micro Powder Inmold-labelling IML-tool closing + injection opening + ejection metal or ceramic foil/film µ-structured mould insert PIM-Feedstock containing Powder 1 foil/film containing Powder 2 Powder 2: functional or nano-particles applied on the structured surface à better accuracy, higher surface quality, functional properties etc. 15 Dr. V. Piotter

16 Process Development Debinding and Sintering procedure adjusted to both tape and feedstock powder 16 Dr. V. Piotter

17 Accuracy tracking mould insert with zig-zag profile original mold insert sintered part green body 17 Dr. V. Piotter

18 Current Results (ZrO 2 ) Present status: - tight connection at the interface - but deviations of the entire part tape tape ceramic feedstock former boundary line feedstock green body sintered part 18 Dr. V. Piotter

19 MicroPIM Future Developments Outlook - Expanding the range of materials functional materials fine and nano powders etc. - Improvement of dimensional accuracy and surface quality - Enhanced multi-component process variants e.g. EU-Projects Multilayer or HITTEG - Practical implementation 19 Dr. V. Piotter

20 Injection Moulding of Micro Components Acknowledgment - Federal Ministry for Education and Research BMBF - European Commission - Deutsche Forschungsgemeinschaft DFG (SFB 499) - Companies Arburg, microparts, Wittmann Battenfeld, RKT, SPT Roth, Junghans, Inmatec etc. - Fraunhofer Institutes IKTS and IFAM - All colleagues at KIT especially Drs. S. Antusch, J. Prokop, and A. Ruh Thank you! 20 Dr. V. Piotter