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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
金属射出成形
Metal Injection Moulding 9

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316LFe、Cr、Ni、Mo耐食性、高強度Common in medical and food industry
Stainless Steel 17-4 PHFe, Cr, Ni, CuHigh strength, good corrosion resistanceUsed in aerospace, automotive
Carbonyl IronFeHigh purity, excellent magnetic propertiesSuitable for electronics, automotive
TungstenWHigh density, high melting pointIdeal for aerospace, defense applications
チタン Ti-6Al-4VTi、Al、VHigh strength-to-weight ratio, corrosion resistanceUsed in medical implants, aerospace
Nickel Alloy IN718Ni, Cr, FeHigh temperature strength, corrosion resistanceSuitable for gas turbines, aerospace
Copper Alloy C18150Cu, CrHigh electrical and thermal conductivityUsed in electrical components
工具鋼 M2Fe, C, W, Mo高硬度、耐摩耗性Used in cutting tools, dies
Cobalt-Chromium AlloyCo, CrHigh strength, biocompatibilityCommon in dental, medical implants
Aluminum Alloy 6061Al、Mg、SiLightweight, good mechanical propertiesUsed 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316L16-18% Cr, 10-14% Ni, 2-3% Mo, Bal. FeCorrosion resistance, good strengthMedical devices, food processing equipment
Stainless Steel 17-4 PH15-17% Cr, 3-5% Ni, 3-5% Cu, Bal. FeHigh strength, corrosion resistanceAerospace, automotive parts
Carbonyl Iron>99% FeHigh purity, magnetic propertiesElectronics, automotive components
Tungsten>99% WHigh density, thermal stabilityAerospace, defense equipment
チタン Ti-6Al-4V90% Ti, 6% Al, 4% V軽量、高強度Medical implants, aerospace parts
Nickel Alloy IN71850-55% Ni, 17-21% Cr, Bal. Fe高温強度Gas turbines, aerospace components
Copper Alloy C1815098-99% Cu, 0.5-1% CrConductivity, thermal propertiesElectrical connectors, heat sinks
工具鋼 M20.75-1.1% 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 Alloy60-65% Co, 27-30% CrStrength, biocompatibility歯科用インプラント、整形外科用器具
Aluminum Alloy 60610.8-1.2% Mg, 0.4-0.8% Si, Bal. AlLightweight, machinabilityAutomotive 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 ProductsWatch 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 StandardsISO 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 ProductsStainless 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-MIMStainless Steel, Tungsten$0.09 – $0.50 per gramインド
ARC Group WorldwideNickel Alloys, Copper Alloys$0.10 – $0.60 per gramアメリカ
CNI ManufacturingStainless Steel, Aluminum$0.08 – $0.48 per gram中国
Kinetics ClimaxTool Steel, Cobalt Alloys$0.12 – $0.58 per gramアメリカ
CMG TechnologiesStainless 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
PrecisionHigh dimensional accuracy, intricate shapesLimited to small and medium-sized parts
材料効率Low material waste, efficient use of powdersHigher initial material cost
機械的特性Strong, durable parts with excellent propertiesSintering process can introduce porosity
Production VolumeSuitable for high-volume productionNot cost-effective for low-volume production
ComplexityCan produce highly complex geometriesLimited to certain part sizes and geometries
表面仕上げExcellent surface finish achievableSecondary finishing might be needed for specific applications
汎用性Wide range of materials availableLonger lead times compared to traditional methods
コストCost-effective for large production runsHigh initial tooling and setup costs
金属射出成形
Metal Injection Moulding 16

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.

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