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This book provides a comprehensive overview of the steps involved in the ceramic injection molding process. It provides the reader with a convenient and authoritative source of information and guidance on the use of materials, equipment and testing procedures to produce satisfactory ceramic products.
Ceramic injection molding (CIM) is a high volume, near net shaping process used to manufacture ceramic parts with complex features and shapes. In CIM design it is important to understand the molding behavior as a function of powder-polymer (feedstock) composition in order to achieve desired part dimensions and properties, at high production rates. Standard practices in CIM product design typically involve performing multiple trial-and-error molding experiments for various feedstock compositions. Alternatively, CIM design simulations can be performed to reduce the iterations. However, they require the measurement of physical, thermal and rheological feedstock properties and the availability of such data is limited. Currently there is no reliable design approach available to perform mold-filling simulations for compositions that differ from those with measured feedstock properties. The present work develops and evaluates a new method to estimate feedstock properties critical to performing CIM simulations. The method utilizes the material properties of ceramic fillers from literature along with experimental measurements of an unfilled wax-polymer binder system. The current work is divided into three parts. In the first part, nine different ceramic feedstocks and a wax-polymer binder, whose material properties were measured by our research group, formed the basis for this study. Experimental and estimated feedstock properties of these nine systems were compared to quantitatively evaluate the quality of correspondence. The second part uses the measured and estimated physical, thermal, and rheological properties for an aluminum nitride feedstock to perform mold-filling simulations to compare the differences in the output of CIM simulations based on the input feedstock property data from experiments and estimates. The third part examines the merits of CIM simulations to predict mold-filling behavior by conducting injection-molding experiments for an aluminum nitride feedstock. The findings from the current study can be used to improve CIM design practices and serve as a guide for estimating ceramic feedstock properties to conduct mold-filling simulations.
This book is composed of different chapters which are related to the subject of injection molding and written by leading international academic experts in the field. It contains introduction on polymer PVT measurements and two main application areas of polymer PVT data in injection molding, optimization for injection molding process, Powder Injection Molding which comprises Ceramic Injection Molding and Metal Injection Molding, ans some special techniques or applications in injection molding. It provides some clear presentation of injection molding process and equipment to direct people in plastics manufacturing to solve problems and avoid costly errors. With useful, fundamental information for knowing and optimizing the injection molding operation, the readers could gain some working knowledge of the injection molding.
This book discusses several new, near-net-shape techniques for fabricating highly reliable, high-performance, complex ceramic parts. In the context of materials design, the creation of high-performance ceramic products of desired shapes has led to the need for new ceramic forming processes. The near-net-shape techniques combine both injection-molding and colloidal-forming processes. Reviewing and summarizing the research and latest advances, the book is divided into 6 parts: (1) the basic theory, development, and application of the colloidal injection molding of ceramics; (2) the tape casting technology; (3) the reliability of the product; (4) the colloidal injection molding of Si3N4 and SiC; (5) low-toxicity systems; and (6) the novel in-situ coagulation casting of ceramic suspensions via controlled release of high-valence counter ions and dispersant removal. It is intended for researchers and graduates in materials science and engineering.