金属射出成形 (MIM) is an advanced manufacturing process used to produce complex, high-precision metal parts. This method combines the versatility of plastic injection molding with the strength and integrity of metal. If you’re curious about how MIM works, its applications, or why it’s becoming a preferred choice in various industries, you’re in the right place. Let’s dive in!
概要 金属射出成形
Metal Injection Moulding (MIM) is a process that blends finely powdered metal with a binder material to create a feedstock that can be shaped and solidified using injection molding. The molded part is then sintered to remove the binder and densify the metal, resulting in a final product with excellent mechanical properties and complex geometries.
Key Advantages of MIM:
- High precision and intricate detailing
- High production rates
- Wide range of material choices
- Reduced material waste
- 優れた機械的特性
応用例 金属射出成形:
MIM is widely used across various industries including automotive, medical devices, electronics, aerospace, and consumer products. Its ability to produce complex shapes with high accuracy makes it ideal for small, intricate parts that require strong mechanical properties.
Types of Metal Powders Used in MIM
When it comes to Metal Injection Moulding, the type of metal powder used plays a crucial role in determining the properties of the final product. Here are some commonly used metal powders in MIM:
| 金属粉 | 構成 | プロパティ | 特徴 |
|---|---|---|---|
| ステンレススチール316L | Fe、Cr、Ni、Mo | 耐食性、高強度 | Common in medical and food industry |
| Stainless Steel 17-4 PH | Fe, Cr, Ni, Cu | High strength, good corrosion resistance | Used in aerospace, automotive |
| Carbonyl Iron | Fe | High purity, excellent magnetic properties | Suitable for electronics, automotive |
| Tungsten | W | High density, high melting point | Ideal for aerospace, defense applications |
| チタン Ti-6Al-4V | Ti、Al、V | High strength-to-weight ratio, corrosion resistance | Used in medical implants, aerospace |
| Nickel Alloy IN718 | Ni, Cr, Fe | High temperature strength, corrosion resistance | Suitable for gas turbines, aerospace |
| Copper Alloy C18150 | Cu, Cr | High electrical and thermal conductivity | Used in electrical components |
| 工具鋼 M2 | Fe, C, W, Mo | 高硬度、耐摩耗性 | Used in cutting tools, dies |
| Cobalt-Chromium Alloy | Co, Cr | High strength, biocompatibility | Common in dental, medical implants |
| Aluminum Alloy 6061 | Al、Mg、Si | Lightweight, good mechanical properties | Used in automotive, consumer electronics |
組成と特性 金属射出成形
Understanding the composition and properties of MIM materials is crucial for selecting the right type for your application. Here’s a detailed look:
| 素材 | 構成 | プロパティ | 用途 |
|---|---|---|---|
| ステンレススチール316L | 16-18% Cr, 10-14% Ni, 2-3% Mo, Bal. Fe | Corrosion resistance, good strength | Medical devices, food processing equipment |
| Stainless Steel 17-4 PH | 15-17% Cr, 3-5% Ni, 3-5% Cu, Bal. Fe | High strength, corrosion resistance | Aerospace, automotive parts |
| Carbonyl Iron | >99% Fe | High purity, magnetic properties | Electronics, automotive components |
| Tungsten | >99% W | High density, thermal stability | Aerospace, defense equipment |
| チタン Ti-6Al-4V | 90% Ti, 6% Al, 4% V | 軽量、高強度 | Medical implants, aerospace parts |
| Nickel Alloy IN718 | 50-55% Ni, 17-21% Cr, Bal. Fe | 高温強度 | Gas turbines, aerospace components |
| Copper Alloy C18150 | 98-99% Cu, 0.5-1% Cr | Conductivity, thermal properties | Electrical connectors, heat sinks |
| 工具鋼 M2 | 0.75-1.1% C, 4.0-6.0% Mo, 5.5-6.75% W, Bal. Fe | 硬度、耐摩耗性 | 切削工具、金型 |
| Cobalt-Chromium Alloy | 60-65% Co, 27-30% Cr | Strength, biocompatibility | 歯科用インプラント、整形外科用器具 |
| Aluminum Alloy 6061 | 0.8-1.2% Mg, 0.4-0.8% Si, Bal. Al | Lightweight, machinability | Automotive parts, consumer electronics |
Applications of Metal Injection Moulding
Metal Injection Moulding is versatile and finds applications in various industries. Here’s a table summarizing some key applications:
| 産業 | 用途 |
|---|---|
| 自動車 | Fuel injector components, turbocharger parts, gearboxes |
| 医療機器 | Surgical instruments, orthodontic brackets, implants |
| エレクトロニクス | Connectors, sensors, mobile phone components |
| 航空宇宙 | Turbine blades, fuel nozzles, fasteners |
| Consumer Products | Watch cases, eyeglass frames, hardware tools |
| ディフェンス | Weapon components, armor-piercing projectiles |
| インダストリアル | Cutting tools, pumps, valves |
Specifications, Sizes, and Standards in MIM
Selecting the right specifications, sizes, and standards is crucial for ensuring the final product meets the required performance criteria. Here’s a detailed look:
| 仕様 | 説明 |
|---|---|
| ASTM規格 | ASTM F2885-11, ASTM B883-10 for MIM materials |
| ISO Standards | ISO 22068, ISO 13320 for powder particle size distribution |
| サイズ | Ranges from 0.1 mm to 100 mm in size depending on complexity |
| 公差 | Typically ±0.3% of dimensions, can be as tight as ±0.05% |
| 表面仕上げ | Can achieve Ra 0.8 to 1.6 micrometers depending on material and process |
| 密度 | Typically ranges from 95% to 99% of theoretical density after sintering |
サプライヤーと価格 金属射出成形
Choosing the right supplier can significantly impact the cost and quality of your MIM components. Here are some notable suppliers along with estimated pricing details:
| サプライヤー | 素材 | 価格 | 地域 |
|---|---|---|---|
| Smith Metal Products | Stainless Steel, Titanium | $0.10 – $0.50 per gram | アメリカ |
| Advanced Metalworking Practices | さまざまな金属粉末 | $0.08 – $0.45 per gram | アメリカ |
| Parmatech Corporation | ステンレス鋼、工具鋼 | $0.12 – $0.55 per gram | アメリカ |
| Indo-MIM | Stainless Steel, Tungsten | $0.09 – $0.50 per gram | インド |
| ARC Group Worldwide | Nickel Alloys, Copper Alloys | $0.10 – $0.60 per gram | アメリカ |
| CNI Manufacturing | Stainless Steel, Aluminum | $0.08 – $0.48 per gram | 中国 |
| Kinetics Climax | Tool Steel, Cobalt Alloys | $0.12 – $0.58 per gram | アメリカ |
| CMG Technologies | Stainless Steel, Titanium | $0.11 – $0.52 per gram | 英国 |
| GKN Sinter Metals | ステンレス鋼、工具鋼 | $0.09 – $0.49 per gram | ドイツ |
| MPP Innovation | さまざまな金属粉末 | $0.10 – $0.47 per gram | アメリカ |
Comparing Pros and Cons of Metal Injection Moulding
When considering Metal Injection Moulding, it’s essential to weigh its advantages and limitations. Here’s a comparison:
| アスペクト | メリット | 制限事項 |
|---|---|---|
| Precision | High dimensional accuracy, intricate shapes | Limited to small and medium-sized parts |
| 材料効率 | Low material waste, efficient use of powders | Higher initial material cost |
| 機械的特性 | Strong, durable parts with excellent properties | Sintering process can introduce porosity |
| Production Volume | Suitable for high-volume production | Not cost-effective for low-volume production |
| Complexity | Can produce highly complex geometries | Limited to certain part sizes and geometries |
| 表面仕上げ | Excellent surface finish achievable | Secondary finishing might be needed for specific applications |
| 汎用性 | Wide range of materials available | Longer lead times compared to traditional methods |
| コスト | Cost-effective for large production runs | High initial tooling and setup costs |
よくある質問
Q: What is Metal Injection Moulding (MIM)?
A: Metal Injection Moulding is a manufacturing process that combines metal
powders with a binder to produce highly detailed and complex metal parts using injection molding techniques.
Q: What materials can be used in MIM?
A: Various materials can be used in MIM, including stainless steels, tool steels, titanium alloys, tungsten, nickel alloys, copper alloys, and more.
Q: What are the key advantages of MIM?
A: The key advantages include high precision, complex geometries, high production rates, reduced material waste, and excellent mechanical properties.
Q: What industries commonly use MIM?
A: MIM is used in automotive, medical devices, electronics, aerospace, consumer products, defense, and industrial applications.
Q: What are the typical sizes and tolerances achievable with MIM?
A: Sizes can range from 0.1 mm to 100 mm, with tolerances typically around ±0.3% of dimensions, and as tight as ±0.05% in some cases.
Q: How does the sintering process affect MIM parts?
A: Sintering removes the binder and densifies the metal, which can introduce porosity but also significantly enhances the mechanical properties of the parts.
Q: Is MIM cost-effective for low-volume production?
A: No, MIM is generally not cost-effective for low-volume production due to high initial tooling and setup costs. It is more suited for high-volume production runs.
Q: Can MIM produce parts with high surface finishes?
A: Yes, MIM can achieve excellent surface finishes, though some applications may require secondary finishing processes for optimal results.
Q: Are there any limitations to the geometries that can be produced with MIM?
A: While MIM can produce highly complex geometries, it is limited to certain part sizes and may not be suitable for very large parts.
Q: What should I consider when selecting a supplier for MIM parts?
A: Consider factors such as material expertise, production capacity, pricing, regional location, and the supplier’s track record in delivering high-quality MIM parts.
結論
Metal Injection Moulding is a versatile and highly efficient manufacturing process that offers numerous benefits for producing complex and high-precision metal parts. From automotive to aerospace, its applications are vast and varied, making it a valuable technique in modern manufacturing. By understanding the types of materials, specifications, and advantages of MIM, you can better assess whether this process is suitable for your specific needs.
Whether you’re considering MIM for its precision, material efficiency, or ability to produce complex geometries, it’s clear that this innovative process has a lot to offer. As technology and materials continue to advance, the potential for Metal Injection Moulding will only grow, opening up new possibilities in manufacturing and design.
