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MIM degreasing and sintering for ceramic hard alloy
The material systems of the currently used MIM degreasing and sintering furnaces mainly include:
Stainless steel, iron-based alloys, magnetic materials, tungsten alloys, hard alloys, fine ceramics and other series.
Cemented carbide, known as “industrial teeth”, is widely used in various fields of the national economy such as engineering, machinery, automobiles, and electronics because of its high hardness and wear resistance. Cemented carbide consumes about half of the tungsten consumption. We use MIM degreasing sintering process to process ceramic hard alloy.
The MIM debinding sintering process uses micron-sized fine powder, which can not only accelerate the sintering shrinkage, help to improve the mechanical properties of the material, prolong the fatigue life of the material, but also improve the wear resistance, stress corrosion resistance and magnetic properties. The applicable materials for MIM degreasing and sintering mainly include: Fe alloy, Fe-Ni alloy, stainless steel, W alloy, Ti alloy, Si-Fe alloy, hard alloy, permanent magnet alloy and ceramic materials such as alumina, silicon nitride and zirconia.
For materials that are too hard, too brittle and difficult to cut, or parts with complex geometric shapes, segregation or contamination of raw materials during casting, the MIM degreasing and sintering process can greatly save costs. Take the processing of typewriter printing component guide rods as an example: usually more than 14 processes are required, while the MIM degreasing and sintering process only needs 6 processes, which can save about half of the cost. As the material cost/manufacturing cost ratio increases, the potential cost reduction is even greater, so the smaller and more complex the part, the better the economics. Through the above analysis, it can be seen that the potential of MIM degreasing and sintering molding is great.
Advantages of MIM degreasing and sintering process
MIM degreased sintered products have high density, good corrosion resistance, high strength and good ductility. 2 or more PM products can be combined into one MIM product, saving materials and processes.
Compared with mechanical processing, MIM degreasing sintering can save materials and reduce weight. The injected gate material can be crushed and used repeatedly without affecting the product performance, and the material utilization rate is high. Form complex products through molds at one time, avoiding multiple processing procedures. It is possible to manufacture complex shaped parts in difficult-to-machine materials.
Products with the following characteristics are usually suitable for MIM debinding and sintering process
Complex shapes: MIM skim sintering allows free design of three-dimensional shapes like injection molding. Since MIM is a molding process, the additional product shape will not increase the cost. If the weight reduction is achieved through shape design, the cost will decrease instead, which makes MIM one of the ideal ways to combine more than one independent part into a multifunctional part. MIM design rules are very close to those of injection molding, making it easy to adapt to tertiary metal parts with complex shapes.
The Dimensional precision: MIM’s near-net shape accuracy is typically ±0.5% of dimension. Certain dimensional features can achieve ±0.3%. Like other technologies, high precision means higher cost, so it is recommended that the dimensional tolerance be moderately relaxed if it can meet the use. Tolerances that cannot be met directly by the MIM degreasing and sintering process can be achieved through subsequent processing.
The Thin-walled products: The wall thickness of less than 6 mm is more suitable for MIM debinding and sintering. Thicker outer walls are also possible, but the process time will be greatly increased and the material cost will increase. Thin walls below 0.5 mm can also be achieved by MIM degreasing and sintering, and Fuchi High-Tech can produce products with extremely thin walls of 0.2 mm (but there is a certain dependence on the specific product shape).
The Weight Size: MIM skim sintering is suitable for parts weighing less than 100 grams, with less than 50 grams being the most common application. However, parts weighing up to 250 grams can also be MIM-processed. Raw materials are a key cost factor for the MIM debinding and sintering process. In the early stage of MIM product design, the weight of components is often reduced as much as possible. As with plastic products, cores and brackets can be used to reduce component weight without compromising product integrity. MIM is outstanding in terms of extremely small and micro components, and the weight is less than 0.1 grams. Products with a length of more than 250mm are also available.
The Batch size: For MIM skim sintering products, the tooling and pre-product development process is necessary for the MIM skim sintering process, so for small batches (less than a few thousand pieces per year), it usually affects the decision process. MIM can be realized very economically from a small output of tens of thousands of pieces per year to an output of tens of millions of pieces.
MIM equipment selection: The MIM degreasing sintering furnace produced by SIMUWU is mainly used for the degreasing sintering process of stainless steel, ferrous, titanium, alloy steel and high-speed steel metal injection molding parts. The quality is guaranteed and trustworthy, and the equipment is easy to manage and maintain, which greatly reduces maintenance costs. SIMUWU company focuses on the manufacture of vacuum furnaces, has more than ten years of relevant experience, and has a good reputation in the field of vacuum furnace manufacturing. The product line includes vacuum air quenching furnace, vacuum oil quenching furnace, vacuum brazing furnace, etc., which are widely sold in developed and developing countries.
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