Sintering Characteristics Of Injection Moulded Components Using Waste Rubber Biopolymer

Nurhashima, Shafiee (2010) Sintering Characteristics Of Injection Moulded Components Using Waste Rubber Biopolymer. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

This research aims to study and investigate the characteristic of injection molded gas atomized stainless steel powder by using the new developed innovative binder system.The optimum heating rate and soaking period used for the sintering process are studied,extensively in this research. The main raw materials used in this research are 17-4 PH stainless steel powder with the new biopolymer binder system which consists of paraffin wax (PW), stearic acid (SA), waste rubber (WR) and polyethylene (PE) mixture. Typically, the mean particles size distribution of 17-4 PH stainless steel powder is less than 22μm at D50. The feedstock that having 65 vol. % of metal powder were injection molded into the tensile test bar. The rapid two stage debinding process that involves the solvent extraction and thermal pyrolisis were conducted to remove the binder. Nine groups of the specimens were then sintered under the vacuum atmosphere in the temperature of 1360 0C at various combinations of heating rates and soaking periods.The specimens primarily were tested for the Critical Properties Analysis – Tensile Test.The highest tensile strength for each group of specimens was selected for further analyses of the morphological effects. The fractures surface microstructure of tested specimens were observed as to understand the fracture behavior, the grain and porosity distribution and the surface morphology and its significant correlation to the resulted mechanical properties. The results showed that the combination of 5 0C/min heating rate and 60 minutes of soaking period gives the higher density value, higher tensile strength,less porosity and homogenous grains distribution of the sintered specimens. Through this research, the development of the injection molding parts could be enhanced for the automotive applications through the establishment of innovative waste rubber new binder system for the metal injection molding parts fabrication.

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