MIM technique is described in which allows for the production of highly porous metallic foams with porosity levels up to 90%. It makes use of the pressure built up by the decomposition of a foaming agent which is incorporated in a foamable precursor copper material obtained by powder compaction. A suitable behaviors feedstock that refers to its rheological is one of the key factors to ensure the successful of MIM technique and to predict failure, whether due to the binder component and compositions, powder loading or unsuitable process parameters. Potassium carbonate and polyethylene is added and were mixed homogeneously to form a copper feedstock. The rheological results in term of shear rate, shear stress, viscosity, melting rate and softening temperature which related to pseduoplastic behaviors have been conducted using a capillary rheometer (CFT-500D, Shimadzu) at various temperature and loads. The result has indicated that the viscosity of the feedstock is decreased with increasing shear rate thus proved the feedstock to be pseudoplastic.
CoCrMo alloy is one of the most used metallic biomaterials due to its high wear. Premature wear of the component is one of the main cause of hip prosthesis failure. The objective in this study is to investigate the tribology properties of sintered CoCrMo fabricated via injection moulding. Tests were carried out at room temperature comparing metal injection moulded dog bone tensile samples at different sintering temperatures. The parameter used for the pin on disk test is a 10kN load, 500m sliding distance and a chromium steel ball as a sliding partner. The morphologies and compositions of the worn surfaces were analysed by optical and scanning electron microscope. The results showed that the wear mechanism and friction coefficient of CoCrMo depended strongly on the microstructure which was influenced by the sintering temperature.
Feedstock preparation is one of the most crucial steps that will influence the metal injection molding process. In this study, the properties of Cu and space holder powder were determined. Powder morphology was captured using Scanning Electron Microscopy (SEM). Three different ratios of feedstocks were premixed with potassium carbonate as space holder using Turbulence Shaker mixer prior to mixing with constant binder system consist of waste rubber (WR). Mixes of three feedstocks with from 40, 50 and 60 wt. % were carried out in Brabender Plasticoder. All feedstocks were mixed at constant powder loading. The feedstocks were successfully injection molded using Vertical Injection Molding machine at 200°C.
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