Variability of powder characteristics and their effect on dimensional variability of powder injection moulded components

Abstract

In this study, the effect of powder characteristics and their variability on the dimensional variability of green and sintered PIM components has been examined for 316L stainless steel. Three lots of gas atomised and three lots of water atomised powders were characterised and used to make six batches of PIM compound. These compound lots were injection moulded using a cavity pressure transducer and screw position regulation controls. The moulded geometry was measured in the green state and sintered state for dimensional variability. The general findings are that gas atomised powder produce less dimensional variability than the water atomised powder from lot to lot, however, the water atomised powders produce less in lot dimensional variability and are generally less susceptible to distortion of cantilevered members during sintering. Also, the lot to lot variation in the powder characteristics, such as particle size and pycnometer density, have an effect on dimensional stability whereas variations in powder characteristics such as surface area, tap and apparent density, and chemistry have little effect on dimensional stability.