金屬陶瓷粉末注射成型技術

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1、金屬（陶瓷）粉末注射成型技術 機械 2010-02-22 02:09:26 閱讀110 評論0 ??字號：大中小?訂閱 1、MIM技術概述 　　金屬（陶瓷）粉末注射成型技術（Metal Injection Molding，簡稱MIM技術）是集塑料成型工藝學、高分子化學、粉末冶金工藝學和金屬材料學等多學科相互滲透與交叉的產物，利用模具可注射成型坯件并通過燒結快速制造高密度、高精度、三維復雜形狀的結構零件，能夠快速準確的將設計思想物化為具有一定結構、功能特性的制品并可直接批量生產出零件，是制造技術行業(yè)一次新的變革。該工藝技術不僅具有常規(guī)粉末冶金工藝工序少、無切削或少切削、經濟效益高等優(yōu)點

2、，而且克服了傳統粉末冶金工藝制品密度低、材質不均勻、機械性能低、不易成型薄壁、復雜結構的缺點，特別適合于大批量生產小型、復雜以及具有特殊要求的金屬零件。 2、MIM工藝過程 2.1 工藝流程 2.2 過程簡介 2.2.1 金屬粉末 　　MIM工藝所用金屬粉末顆粒尺寸一般在0.5~20μm，從理論上講，顆粒越細，比表面積也越大，易于成型和燒結。而傳統的粉末冶金工藝則采用大于40μm的較粗的粉末。 2.2.2 有機膠粘劑 　　有機粘接劑作用是粘接金屬粉末顆粒，使混合料在注射機料筒中加熱具有流變性和潤滑性，也就是說帶動粉末流動的載體。因此，粘接劑的選擇是整個粉末

3、注射成型的關鍵。對有機粘接劑要求：①用量少，即用較少的粘接劑能使混合料產生較好的流變性；②不反應，在去除粘接劑的過程中與金屬粉末不起任何化學反應；③易去除，在制品內不殘留碳。 2.2.3 混煉與制粒 　　混煉時把金屬粉末與有機粘接劑均勻摻混在一起，將其流變性調整到適于注射成型狀態(tài)的作用，混合料的均勻程度直接影響其流動性，因而影響注射成型工藝參數乃至最終材料的密度及其它性能，注射成型過程中產生的下角料、廢品都可重新破碎、制粒，回收再用。 2.3.4 注射成型 　　本步工藝過程與塑料注射成型工藝過程在原理上是一致的，其設備條件也基本相同。在注射成型過程中，混合料在注射機料筒內被加熱

4、成具有流變性的塑性物料，并在適當的注射壓力下注入模具中，成型出毛坯。注射成型的毛坯的密度在微觀上應均勻一致，從而使制品在燒結過程中均勻收縮?？刂谱⑸錅囟取⒛＞邷囟?、注射壓力、保壓時間等成型參數對獲得穩(wěn)定的生坯重量至關重要。要防止注射料中各組分的分離和偏析，否則將導致尺寸失控和畸變而報廢。 2.2.5 脫粘 　　成型毛坯在燒結前必須去除毛坯內所含有的有機粘接劑，該過程稱為脫粘。脫粘工藝必須保證粘接劑從毛坯的不同部位沿著顆粒之間的微小通道逐漸地排出，而不降低毛坯的強度。溶劑萃取部分粘接劑后，還要經過熱脫粘除去剩余的粘接劑。脫粘時要控制坯件中的碳含量和減少氧含量。 2.2.6 燒結

5、　　燒結是在通有可控氣氛的燒結爐中進行的。MIM零件的高密度化是通過高的燒結溫度和長的燒結時間來達到的，從而大大提高和改善零件材料的力學性能。 2.2.7 后處理 　　對于尺寸要求較為精密及有特殊性能要求的零件，需要進行必要的后處理。本工序與常規(guī)金屬制品的熱處理工序相同。 3、MIM工藝特點 3.1 MIM工藝與其它加工工藝的對比 3.1.1 MIM與傳統的粉末冶金（PM）的比較 　　MIM使用的原料粉末粒徑在2—15μm，而傳統粉末冶金的原料粉末粒徑大多在50—100μm。MIM工藝的成品密度高，原因是使用微細粉末。形狀上自由度高是傳統粉末冶金所不能達到的，表1為

6、兩工藝的比較。 3.1.2 MIM與精密鑄造的比較 　　在金屬成型工藝中，壓鑄和精密鑄造是可以成型三維復雜形狀的零件，但壓鑄僅限于低熔點金屬，而精密鑄造（IC）限于合金鋼、不銹鋼、高溫合金等高熔點金屬及有色金屬，對于難熔合金如硬質合金、高密度合金、金屬陶瓷等卻無能為力，這是IC的本質局限性，而且IC對于很小、很薄、大批量的零件生產是十分困難或不可行的。IC產業(yè)化已成熟，發(fā)展的潛力有限。MIM是新興的工藝，將擠入IC大批量小零件的市場。 3.1.3 MIM與傳統機械加工的比較 　　傳統機械加工法，近來靠自動化而提升其加工能力，在效率和精度上有極大的進步，但是基本的程序

7、上仍脫不開逐步加工（車削、刨、銑、磨、鉆孔、拋光等）完成零件形狀的方式。機械加工方法的加工精度遠優(yōu)于其他加工方法，但是因為材料的有效利用率低，且其形狀的完成受限于設備與刀具，有些零件無法用機械加工完成。相反的，MIM可以有效利用材料，形狀自由度不受限制。對于小型、高難度形狀的精密零件的制造，MIM工藝比較機械加工而言，其成本較低且效率高，具有很強的競爭力。 　　MIM技術彌補了傳統加工方法在技術上的不足或無法制作的缺憾，并非只與傳統加工方法競爭，MIM技術可以在傳統加工方法無法制作的零件領域發(fā)揮其特長。 　　 其工藝特點與其它工藝的比較如下圖： 3.2 MIM的優(yōu)點

8、　　從MIM的工藝本質分析，是目前最適合于大批量生產高熔點材料，高強度、復雜形狀零件的工藝，其優(yōu)點可歸納如下： （1）MIM可以成型三維形狀復雜的各種金屬材料零件（只要這種材料能被制成細粉）。零件各部位的密度和性能一致，既各向同性。為零件設計提供了較大的自由度。 （2）MIM能最大限度制得接近最終形狀的零件，尺寸精度較高。 （3）即使是固相燒結，MIM制品的相對密度可達95%以上，其性能可與鍛造材料相媲美。特別是動力學性能優(yōu)良。 （4）粉末冶金（PM）的自動模壓機的價格比注射成型機要高數倍。MIM可方便地采用一模多腔模具，成型效率高，模具使用壽命長，更換調整模具方便快捷。

9、（5）注射料可反復使用，材料利用率達98%以上。 （6）產品轉向快。生產靈活性大，新產品從設計到投產時間短。 （7）MIM特別適合于大批量生產，產品性能一致性好。如果生產的零件選擇適當，數量大，可取得較高的經濟效益。 （8）MIM所用材料范圍寬，應用領域廣闊。可用于注射成型的材料非常廣泛，如碳鋼、合金鋼、工具鋼、難熔合金、硬質合金、高比重合金等。MIM制品的應用領域已經遍及國民經濟各領域。 　　選擇何種金屬成型工藝，零件的復雜性和生產產量是兩個主要決定因素。MIM工藝在零件生產量大和復雜程度高時獨占優(yōu)勢。對于零件設計者，應著重設計三維形狀復雜的生產量大的零件，以充分發(fā)揮MIM工

10、藝的特點，取得降低生產成本和提高產品性能的效果。 4、注射成型制品材料性能與成本分析 　　MIM工藝采用微米級細粉末，既能加速燒結收縮，有助于提高材料的力學性能，延長材料的疲勞壽命，又能改善耐磨性、抗應力腐蝕及磁性能。MIM適用的材料主要有：Fe合金、Fe-Ni合金、不銹鋼、W合金、Ti合金、Si-Fe合金、硬質合金、永磁合金及氧化鋁、氮化硅、氧化鋯等陶瓷材料。表2列出了一些MIM材料的基本性能。 　　對于過硬、過脆難以切削的材料或幾何形狀復雜、鑄造時原料有偏析或污染的零件，采用MIM工藝可大幅度節(jié)約成本。以加工打字機印刷元件導桿為例：通常需14道以上工序，而采用MIM

11、工藝只需6道工序，可節(jié)約成本一半左右。當材料成本/制造成本的比率增加時，潛在的成本更能降低，因此零件越小越復雜，經濟效益將越好。通過以上分析，可以看出MIM成型的潛力是很大的。 5、應用領域 　MIM技術的應用領域： 1、汽車用零件：安全氣囊用零件、汽車鎖用零件、安全帶用零件、汽車車門升降系統、小齒輪、汽車用空調系統小零件、剎車系統中齒條等，供油系統中的傳感器中的小零件； 2、軍用零件：槍支零件、彈用零件、引信用零件； 3、計算機及IT行業(yè)：如打印機零件、磁芯、撞針軸銷、驅動零件、光通信陶瓷插頭； 4、工具：如鉆頭、刀頭、噴嘴、螺旋銑刀、汽動工具、漁具用的零件等；

12、 5、家用器具：如表殼、表鏈、電動牙刷、剪刀、高爾夫球頭、珠寶鏈環(huán)、刃具刀頭等零部件； 6、醫(yī)療機械用零件：如牙矯形架、剪刀、鑷子； 7、電氣用零件：微型馬達、傳感器件； 8、機械用零件：如紡織機、卷邊機、辦公機械用零件等； 引文來源??濟南博泰精密制造科技有限公司 金屬粉末注射成形 機械 2010-02-21 11:46:23 閱讀17 評論0 ??字號：大中小?訂閱 工藝流程 ? 生產流程 機器實物圖 ? 一 混料過程 ? ? ? · 喂料：將大約60％的金屬粉末與40％的粘結劑混合成均質的喂

13、料。 二 注射成形 ? · 注射成形：將喂料置入注射成形機進行注射成形，此過程類似注塑加工。零件的形狀和結構在模具中成形。 三 脫粘過程 ? · 脫粘：運用物理或者化學方法脫除零件中的粘結劑，零件由金屬粉末與粘結劑的混合物變?yōu)閱渭兊慕饘倭慵?，體積發(fā)生收縮，形狀和結構不變。 四 燒結過程 ? · 燒結：此流程是將零件致密化處理，體積進一步收縮，形狀和結構不變，此時相對密度≥95％。 ? 引文來源??www.pvd-mim （英文版 ） Two regulations promulgated f

14、or implementation is in the party in power for a long time and the rule of law conditions, the implementation of comprehensive strictly strategic plan, implementation in accordance with the rules and discipline to manage the party, strengthen inner-party supervision of major initiatives. The two reg

15、ulations supporting each other, the < code > adhere to a positive advocate, focusing on morality is of Party members and Party leading cadres can see, enough to get a high standard; < rule > around the party discipline, disciplinary ruler requirements, listed as "negative list, focusing on vertical

16、gauge, draw the party organizations and Party members do not touch the" bottom line ". Here, the main from four square face two party rules of interpretation: the first part introduces two party Revised regulations the necessity and the revision process; the second part is the interpretation of the

17、two fundamental principles of the revision of laws and regulations in the party; the third part introduces two party regulations modified the main changes and needs to grasp several key problems; the fourth part on how to grasp the implementation of the two regulations of the party. < code > and < R

18、egulations > revised the necessity and revised history of the CPC Central Committee the amendment to the Chinese Communist Party members and leading cadres honest politics several guidelines > and < Chinese Communist Party discipline and Punishment Regulations > column 1 by 2015 to strengthen party

19、laws and regulations focus. Two party regulations revision work lasted a Years, pooling the wisdom of the whole party, ideological consensus, draw historical experience, respect for the wisdom of our predecessors, which reflects the unity of inheritance and innovation; follow the correct direction,

20、grasp the limited goals, adhere to the party's leadership, to solve the masses of the people reflect a focus on the problem. The new revision of the < code > and < rule >, reflects the party's 18 and the eighth session of the third, the spirit of the fourth plenary session, reflecting the experience

21、 of studying and implementing the General Secretary Xi Jinping series of important speech, reflects the party's eighteen years comprehensive strictly practice. (a) revised two regulations of the party need of < the ICAC guidelines > in < in 1997 Leaders as members of the Communist Party of China cle

22、an politics certain criteria (Trial) > based on revised, the promulgation and implementation of January 2010, to strengthen the construction of the contingent of leading cadres play an important role. But with the party to manage the party strictly administering the deepening, has not been able to f

23、ully meet the actual needs. Content is too complicated, "eight prohibition, 52 are not allowed to" hard to remember, and also difficult to put into practice; the second is concisely positive advocated by the lack of prohibited provisions excessive, no autonomy requirements; the third is banned terms

24、 and discipline law, both with the party discipline, disciplinary regulations repeat and Criminal law and other laws and regulations repeat; the fourth is to "clean" the theme is not prominent, not for the existing problems, and is narrow, only needle of county-level leading cadres above. < rule > i

25、s in 1997 < Chinese Communist Party disciplinary cases (Trial) > based on revision, in December 2003 the promulgation and implementation, to strengthen the construction of the party play very important role. Along with the development of the situation, which many provisions have been unable to fully

26、 meet the comprehensive strictly administering the practice needs. One is Ji law, more than half of the provisions and criminal law and other countries laws and regulations Repetition; two is the political discipline regulations is not prominent, not specific, for violation of the party constitution

27、, damage the authority of Party Constitution of misconduct lack necessary and serious responsibility to pursue; third is the main discipline for the leading cadres, does not cover all Party members. Based on the above situation, need to < the criterion of a clean and honest administration > and < ru

28、le > the two is likely to be more relevant regulations first amendment. By revising, really put the authority of Party discipline, the seriousness in the party tree and call up the majority of Party members and cadres of the party constitution of party compasses party consciousness. (II) two party r

29、egulations revision process the Central Committee of the Communist Party of China attaches great importance to two regulations revision . Xi Jinping, general books recorded in the Fifth Plenary Session of the eighth session of the Central Commission for Discipline Inspection, on the revised regulati

30、ons < > made clear instructions. According to the central deployment, the Central Commission for Discipline Inspection from 2014 under six months begin study two regulations revision. The Standing Committee of the Central Commission for Discipline Inspection 4 review revised. Comrade Wang Qishan 14

31、times held a special meeting to study two regulations revision, amendment clarifies the direction, major issues of principle, path and target, respectively held a forum will listen to part of the province (area) secretary of the Party committee, Secretary of the Discipline Inspection Commission, par

32、t of the central ministries and state organs Department The first party committee is mainly responsible for people, views of experts and scholars and grassroots party organizations and Party members. Approved by the Central Committee of the Communist Party of China, on 7 September 2015, the gene

33、ral office of the Central Committee of the Party issued a notice to solicit the provinces (autonomous regions, municipalities) Party, the central ministries and commissions, state ministries and commissions of the Party (party), the General Political Department of the military, every 3 people organi

34、zation of Party of two regulations revision opinion. Central Commission for Discipline Inspection of extensive solicitation of opinions, careful study, attracting, formed a revised sent reviewers. In October 8 and October 12, Central Committee Political Bureau Standing Committee and the Political Bu

35、reau of the Central Committee After consideration of the two regulations revised draft. On October 18, the Central Committee of the Communist Party of China formally issued two regulations. Can say, two laws amendment concentrated the wisdom of the whole party, embodies the party. Second, < code > a

36、nd < Regulations > revision of the basic principles of two party regulations revision work and implement the party's eighteen, ten eight plenary, the spirit of the Fourth Plenary Session of the Eleventh Central Committee and General Secretary Xi Jinping important instructions on the revised < low po

37、litical criterion > and < Regulations >, highlighting the ruling party characteristics, serious discipline, the discipline quite in front of the law, based on the current, a long-term, advance as a whole, with Bu Xiuding independent < rule > and < rule >. Main principle is: first, adhere to the part

38、y constitution to follow. The constitution about discipline and self-discipline required specific, awaken the party constitution of party compasses party consciousness, maintaining the authority of the constitution. General Secretary Xi Jinping pointed out that "no rules, no side round. Party consti

39、tution is the fundamental law, the party must follow the general rules. In early 2015 held the eighth session of the Central Commission for Discipline Inspection Fifth Plenary Session of the 16th Central Committee, Xi Jinping again pointed out that constitution is the party must follow the general r

40、ules, but also the general rules." the revision of the < code > and < rule > is Method in adhere to the regulations established for the purpose of combining rule of virtue is to adhere to the party constitution as a fundamental to follow, the constitution authority set up, wake up the party constitu

41、tion and party rules the sense of discipline, the party constitution about discipline and self-discipline specific requirements. 4 second is to adhere to in accordance with the regulations governing the party and the party. The Party of rule of virtue "de", mainly refers to the party's ideals and be

42、liefs, excellent traditional style. The revised the < code > closely linked to the "self-discipline", insisting on the positive initiative, for all members, highlight the "vital few", emphasized self-discipline, focusing on the morality, and the majority of Party members and the ideological and mora

43、l standards. The revised < > Ji method separately, Ji, Ji Yan to Method, as a "negative list", emphasizing the heteronomy, focusing on vertical gauge. Is this one high and one low, a positive reaction, the strict party discipline and practice results transformation for the integration of the whole p

44、arty to observe moral and discipline requirements, for the majority of Party members and cadres provides benchmarking and ruler. Third, insist on to. In view of the problems existing in the party at the present stage, the main problems of Party members and cadres in the aspect of self-discipline and

45、 abide by the discipline to make clearly defined, especially the party's eighteen years strict political discipline and political rules, organization and discipline and to implement the central eight provisions of the spirit against the four winds and other requirements into Disciplinary provisions.

46、 Not one pace reachs the designated position, focusing on in line with reality, pragmatic and effective. After the revision of major changes, major changes in the < code > and < rule > modified and needs to grasp several key problems (a) < code > < code > adhere to according to regulations governing

47、 the party and party with morals in combination, for at the present stage, the leadership of the party members and cadres and Party members in existing main problems of self-discipline, put forward principles, requirements and specifications, showing Communists noble moral pursuit, reflected at all

48、times and in all over the world ethics from high from low 5 common requirements. One is closely linked to the "self-discipline", removal and no direct relation to the provisions of . the second is adhere to a positive advocate, "eight prohibition" 52 are not allowed to "about the content of the" neg

49、ative list moved into synchronization amendment < cases >. Three is for all the party members, will apply object from the leadership of the party members and cadres to expand to all Party members, fully embodies the comprehensive strictly required. The fourth is prominent key minority, seize the lea

50、dership of the party members and cadres is the key, and put forward higher requirements than the ordinary Party members. Five is to simplify, and strive to achieve concise, easy to understand, easy to remember. The revised < code > is the ruling Party since the first insists on a positive advocate f

51、orAll Party members and the self-discipline norms, moral declaration issued to all members of the party and the National People's solemn commitment. > < criterion of a clean and honest administration consists of 4 parts, 18, more than 3600 words. After the revision of the < code >, a total of eight,

52、 281 words, including lead, specification and Party member cadre clean fingered self-discipline norms, etc. Part 3 members low-cost clean and self-discipline, the main contents can be summarized as "four must" "eight code". Lead part, reiterated on ideal and faith, fundamental purpose, the fine trad

53、itions and work style, noble sentiments, such as "four must" the principle of requirements, strong tone of self-discipline, The higher request for 6 and supervised tenet, the foothold in permanent Bao the party's advanced nature and purity, to reflect the revised standards requirements. Members of s

54、elf-discipline norms around the party members how to correctly treat and deal with the "public and private", "cheap and rot" thrifty and extravagance "bitter music", put forward the "four norms". Party leader cadre clean fingered self-discipline norms for the leadership of the party members and cadr

55、es of the "vital few", around the "clean politics", from civil servant of the color, the exercise of power, moral integrity, a good family tradition and other aspects of the leadership of the party members and cadres of the "four norms" < > < norm norm. "The Party member's self-discipline norms" and

56、 "party members and leading cadre clean fingered self-discipline norms," a total of eight, collectively referred to as the "eight". "Four must" and "eight" of the content from the party constitution and Party's several generation of leaders, especially Xi Jinping, general secretary of the important

57、discussion, refer to the "three discipline and eight points for attention" statements, and reference some embody the Chinese nation excellent traditional culture essence of epigrams. (2) the revised regulations, the main changes in the revised Regulations > to fully adapt to the strictly requirement

58、s, reflects the according to the regulations governing the law of recognition of deepening, the realization of the discipline construction and Jin Ju. < rule > is party a ruler, members of the basic line and follow. And the majority of Party members and cadres of Party organizations at all levels sh

59、ould adhere to the bottom line of thinking, fear discipline, hold the bottom line, as a preventive measure, to keep the party's advanced nature and purity. 1, respect for the constitution, refinement and discipline. Revised < rule > from comprehensive comb physical constitution began, the party cons

60、titution and other regulations of the Party of Party organizations and Party discipline requirements refinement, clearly defined in violation of the party constitution will be in accordance with regulations to give the corresponding disciplinary action. The original 10 categories of misconduct, inte

61、gration specification for political discipline, discipline, honesty and discipline masses Ji Law and discipline and discipline and other six categories, the content of < rule > real return to Party discipline, for the majority of Party members and listed a "negative list. 7 2, highlighting the polit

62、ical discipline and political rules. > < Regulations according to the stage of the discipline of outstanding performance, emphasizing political discipline and political rules, organization and discipline, in opposition to the party's leadership and the party's basic theory, basic line, basic program

63、 and basic experience, the basic requirement of behavior made prescribed punishment, increase the cliques, against the organization such as violation of the provisions, to ensure that the central government decrees and the Party of centralized and unified. 3, adhere to strict discipline in the law a

64、nd discipline In front, Ji separated. Revised < Regulations > adhere to the problem oriented, do Ji separated. Any national law existing content, will not repeat the provisions, the total removal of 79 and criminal law, repeat the content of the public security management punishment law, and other l

65、aws and regulations. In the general reiterated that party organizations and Party members must conscientiously accept the party's discipline, die van comply with national laws and regulations; at the same time, to investigate violations of Party members and even criminal behavior of Party discipline

66、 and responsibility, > < Regulations distinguish five different conditions, with special provisions were made provisions, so as to realize the connection of Party discipline and state law. 4, reflect Wind building and anti-corruption struggle of the latest achievements. < rule > the party's eighteen years implement the spirit of the central provisions of the eight, against the requirements of the "four winds" and transformation for disciplinary provisions, reflecting the style construction is al