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Abstract - Industry trends indicate the need for economical fine powder grades for a growing number of applications.
Particle size, shape and percentage yields are the important characteristics associated with the manufacture of suitable
powders. This work identifies our development efforts, corresponding achievements and commercial applications. Various
metal injection molding binder formulations, to be used in conjunction with the fine powders, are also reviewed.
KEYWORDS: ATOMIZATION, METAL INJECTION MOLDING, METAL POWDERS, FEEDSTOCK
High-pressure water atomization has proven to be a Results of our fine particle iron (FPI) material
viable, low-cost process to achieve fine particle size development effort indicate high pressure water
distributions for iron, stainless and low-alloy metal atomization, with an optimized product yield, represents
powders. The economic advantages and prealloying somewhat coarser particle size distribution than gas
capability provide desirable advantages over competing atomized powders, Figure 1. It should be emphasized,
technologies. Previous shortcomings relative to powder that not all particle size comparisons are truly
characteristics, i.e. irregular particle shape, lower tap representative. Often values are misleading because not
densities, oxidized surfaces, have been refined to more all powder producers use the same reporting or
closely replicate gas atomized powder properties. identification practices when referencing particle size
Internal development efforts focused on more distribution. Figure 2 represents the actual laser
sophisticated alloy compositions, improved melting diffraction results of water atomized 316L.
practices and further development of water atomizing
techniques. This work identified useful process control 100
guidelines that assist in achieving desired particle 90
characteristics. Understanding the interrelated variables 80
was the key to our successful effort. 70
60 Gas 316L
susceptibility to oxidation. 8 50
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Figure 4 - Surface Modified FPI material Figure 6 - Surface area versus Oxygen
with 45% less surface area. content.
1.2 9.95 8.85
316L Gas Atomized
9.94 8.84
1
9.93 8.83
9.9 8.8
0.4 9.89
FPI 17-4 PH 8.79
9.88 8.78
0.2
9.87 8.77
0 9.86 8.76
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
10
13
16
19
22
25
28
31
34
37
40
43
46
49
52
55
58
1
7
Part Number
9.92 9.32
G
z
FPI 316L
thickness can be modified with specific additions or e
d 9.86 9.26
9.84 9.24
oxygen content of an iron based powder with small
additions of a proprietary oxide forming element(s) made 9.82 9.22
V. SUMMARY