Skip to main content
SpringerLink
Log in

Experimental analysis and numerical simulation of sintered micro-fluidic devices using powder hot embossing process

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

For the past 2 years, interest in manufacturing technologies based on micro-fluidic systems has been continuously increasing. Today, micro-fluidic systems are used in numerous biomedical and pharmaceutical applications. Micro-fluidics cannot be thought about separately without advances in micro- and nano-fabrication. Investigations based on experiments, finite element modelling and simulations of powder hot embossing process (PHE) were performed to optimise the sintering step and processing parameters of micro-fluidic components. The model pertaining to thermo-elasto-viscoplastic behaviour was identified for 316L stainless steel powders. In this regard, different material properties such as sintering stress, bulk, and shearing viscosities were identified by inverse analysis from present dilatometer measurements using beam-bending and free sintering tests. The identification of materials was performed for various powder volume loadings and kinetic rates for different 316L elaborated feedstock, and the parameters were obtained as functions of relative density. The initial inhomogeneity due to the PHE process has been taken into account in the sintering simulation, as it affects the final shrinkage of the sintered components. The solid-state sintering simulations were investigated for various final sintering temperatures and kinetic rates to obtain high and homogeneous relative density distributions, achieve isotropic shrinkage and optimise the sintering process parameters. The numerical simulations were realised based on the identified parameters on a 3D micro-structured specimen with an associated rectangular plate support elaborated by PHE; this allowed a comparison between the numerical predictions and the experimental results for the sintering stage. The finite element simulation results of the sintering stage with a micro-fluidic structured component at a high final temperature (1360 °C) are in excellent agreement with the results of the experiments. The comparison of the simulation and experimental results validated the identified and implemented physical model and proposed methodologies.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Liu C-H, Chen W, Su W, Sun C-N (2015) Numerical and experimental analysis of the automated demolding process for PDMS microfluidic devices with high-aspect ratio micropillars. Int J Adv Manuf Technol 80:401–409

    Article  Google Scholar 

  2. Ohno K, Tachikawa K, Manz A (2008) Microfluidics: applications for analytical purposes in chemistry and biochemistry. Electrophoresis 29:4443–4453

    Article  Google Scholar 

  3. Chen P-C, Pan C-W, Lee W-C, Li K-M (2014) An experimental study of micromilling parameters to manufacture microchannels on a PMMA substrate. Int J Adv Manuf Technol 71:1623–1630

    Article  Google Scholar 

  4. Jáuregui AL, Siller HR, Rodríguez CA, Elías-Zúñiga A (2010) Evaluation of micromechanical manufacturing processes for microfluidic devices. Int J Adv Manuf Technol 48:963–972

    Article  Google Scholar 

  5. Armillotta A, Baraggi R, Fasoli S (2014) SLM tooling for die casting with conformal cooling channels. Int J Adv Manuf Technol 77(1):573–583

    Article  Google Scholar 

  6. Li JM, Liu C, Peng J (2008) Effect of hot embossing process parameters on polymer flow and microchannel accuracy produced without vacuum. J Mater Process Technol 207:163–171

    Article  Google Scholar 

  7. Ou H, Sahli M, Gelin J-C, Barrière T (2014) Experimental analysis and finite element simulation of the co-sintering of bi-material components. Powder Technol 268:269–278

    Article  Google Scholar 

  8. Raza M-R, Sulong A-B, Muhamad N, Akhtar M-N, Rajabi J (2015) Effects of binder system and processing parameters on formability of porous Ti/HA composite through powder injection moulding. Mater Des 87:386–392

    Article  Google Scholar 

  9. Sahli M, Gelin J-C, Barriere T (2013) Characterisation and replication of metallic microfluidic devices using three different powders processed by hot embossing. Powder Technol 246:284–302

    Article  Google Scholar 

  10. Kurgan N (2013) Effects of sintering atmosphere on microstructure and mechanical property of sintered powder metallurgy 316L stainless steel. Mater Des 52:995–998

    Article  Google Scholar 

  11. Sahli M, Gelin J-C, Barrière T (2015) Replication of microchannel structures in WC–co feedstock using elastomeric replica moulds by hot embossing process. Mater Sci Eng C 55:252–266

    Article  Google Scholar 

  12. Choi J-P, Lee G-Y, Song J-I, Lee W-S, Lee J-S (2015) Sintering behavior of 316L stainless steel micro–nanopowder compact fabricated by powder injection moulding. Powder Technol 279:196–202

    Article  Google Scholar 

  13. Rajabi J, Muhamad N, Sulong A-B, Fayyaz A, Raza M-R (2014) The effect of nano-sized stainless steel powder addition on mechanical and physical properties of micropowder injection molded part. Mater Des 63:223–232

    Article  Google Scholar 

  14. Kurgan N (2014) Effect of porosity and density on the mechanical and microstructural properties of sintered 316L stainless steel implant materials. Mater Des 55:235–241

    Article  Google Scholar 

  15. Xie F, He X, Cao S, Qu X (2013) Structural and mechanical characteristics of porous 316L stainless steel fabricated by indirect selective laser sintering. J Mater Process Technol 213:838–843

    Article  Google Scholar 

  16. Coble RL (1961) Sintering crystalline solids. I. Intermediate and final state diffusion models. J Appl Phys 32:787–792

    Article  Google Scholar 

  17. German RM (1996) Sintering theory and practices. John Wiley, New York

    Google Scholar 

  18. R. M. German (1996) Sintering theory and practice, ISBN 0-471-05786-X. Wiley-VCH, 568

  19. Wakai F (2013) Mechanics of viscous sintering on the micro- and macro-scale. Acta Mater 61:239–247

    Article  Google Scholar 

  20. Gasik M, Baosheng Z (2000) A constitutive model and FE simulation for the sintering process of powder compacts. Comput Mater Sci 8:93–101

    Article  Google Scholar 

  21. Heaney DF, Spina R (2007) Numerical analysis of debinding and sintering of MIM parts. J Mater Process Technol 191:385–389

    Article  Google Scholar 

  22. Reiterer M, Kraft T, Janosovits U, Riedel H (2004) Finite element simulation of cold isostatic pressing and sintering of SiC components. Ceram Int 30:177–183

    Article  Google Scholar 

  23. Bruchon J, Pino-Munoz D, Valdivieso F, Drapier S (2010) Finite element simulation of mass transport during sintering of a granular packing. Part I. Surface and lattice diffusions. J Am Ceram Soc 13:1–23

    Google Scholar 

  24. Khoei AR (2002) Numerical simulation of powder compaction processes using an inelastic finite element analysis. Mater Des 23:523–529

    Article  Google Scholar 

  25. Mamen B, Barriere T, Gelin JC (2013) Investigations on thermal debinding process for fine 316L stainless steel feedstocks and identification of kinetic parameters from coupling experiments and finite element simulations. Powder Technol 235:192–202

    Article  Google Scholar 

  26. German RM (2002) Computer modeling of sintering processes. Int J Powder Metall 38:48–66

    Google Scholar 

  27. Mamen B, Song J, Barriere T, Gelin J-C (2015) Experimental and numerical analysis of the particle size effect on the densification behaviour of metal injection moulded tungsten parts during sintering. Powder Technol 270:230–243

    Article  Google Scholar 

  28. Kraft T, Riedel H (2004) Numerical simulation of solid state sintering: model and application. J Eur Ceram Soc 24:345–361

    Article  Google Scholar 

  29. Tsvelikh A, Thompson W, Easton A, Freshwater I (1995) A geometrical finite element model of the sintering process of advanced ceramics. Comput Mater Sci 3:457–464

    Article  Google Scholar 

  30. Ozkan N, Briscoe BJ (1994) Rheological analysis of ceramic pastes. J Eur Ceram Soc 14:143–151

    Article  Google Scholar 

  31. Ozkan N, Briscoe BJ (1997) Overall shape of sintered alumina compacts. Ceram Int 23:521–536

    Article  Google Scholar 

  32. German RM, Lathrop JF (1978) Simulation of spherical powder sintering by surface diffusion. J Mater Sci 13:921–929

    Article  Google Scholar 

  33. Bouvard D, McMeeking RM (1996) Deformation of interparticle necks by diffusion controlled creep. J Am Ceram Soc 79:666–672

    Article  Google Scholar 

  34. Shimosaka A, Sawai T, Hidaka J (1995) Computer simulation of the initial stage sintering of particles. J Soc Powder Technol 32:668–674

    Article  Google Scholar 

  35. Ch’ng HN, Pan J (2007) Sintering of particles of different sizes. Acta Mater 55:813–824

    Article  Google Scholar 

  36. Pan J, Cocks ACF, Kucherenko S (1997) Finite element formulation of coupled grain boundary and surface diffusion with grain-boundary migration. Proc Roy Soc A 453:2161–2184

    Article  MathSciNet  Google Scholar 

  37. Wang YU (2006) Computer modeling and simulation of solid-state sintering: a phase field approach. Acta Mater 54:953–961

    Article  Google Scholar 

  38. Asp K, Agren J (2006) Phase-field simulation of sintering and related phenomena-a vacancy diffusion approach. Acta Mater 54:1241–1248

    Article  Google Scholar 

  39. Nomoto S (2010) Application of multi-phase-field method to sintering. JSME 23th Computational Mechanics Division Conference 23:105–106

  40. Wang C, Cheng L, Zhao Z (2010) FEM analysis of the temperature and stress distribution in spark plasma sintering: modelling and experimental validation. Comput Mater Sci 49:351–362

    Article  Google Scholar 

  41. Muñoz S, Anselmi-Tamburini U (2010) Temperature and stress fields evolution during plasma sintering processes. J Mater Sci 45:6528–6539

    Article  Google Scholar 

  42. Song J, Gelin JC, Barrière T, Liu B (2006) Experiments and numerical modelling of solid state sintering for 316L stainless steel components. J Mater Process Technol 177:352–355

    Article  Google Scholar 

  43. Barriere T, Liu B, Gelin J-C (2003) Determination of the optimal process parameters in metal injection molding from experiments and numerical modeling. J Mater Process Technol 144:636–644

    Article  Google Scholar 

  44. Schoenberg SE, Green DJ, Segall AE, Messing GL, Grader AS, Halleck PM (2006) Stresses and distortion due to green density gradients during densification. J Am Ceram Soc 89:3027–3033

    Article  Google Scholar 

  45. Toussaint F, Bouvard D, Tenaud P, Di Marcello E (2004) Experimental and numerical analysis of the deformation of ferrite segments during sintering. J Mater Process Technol 147:72–78

    Article  Google Scholar 

  46. Yu PC, Li QF, Fuh JYH, Li T, Lu L (2007) Two-stage sintering of nano-sized yttria stabilized zirconia process by powder injection moulding. J Mater Process Technol 192:312–318

    Article  Google Scholar 

  47. Skorokhod VV, Olevskii EA, Shtern MB (1993) Continuum theory of sintering. I. Phenomenological model. Analysis of the effect of external forces on the kinetics of sintering. Powder Metall Met Ceram 32:21–26

    Article  Google Scholar 

  48. Sofronis P, McMeeking RM (1992) Creep of power-law material containing spherical voids. J Appl Mech 59:88–95

    Article  Google Scholar 

  49. Olevsky EA (1998) Theory of sintering: from discrete to continuum. Mater Sci Eng 23:41–100

    Article  Google Scholar 

  50. Skorohod VV, Olesvsky EA, Shtern MB (1991) Continnum theory for sintering of the porous bodies: model and application. Sci Sinter 23:79–91

    Google Scholar 

  51. Gasik M, Zhang B (2000) A constitutive model and FE simulation for the sintering process of powder compacts. Comput Mater Sci 18:93–101

    Article  Google Scholar 

  52. Bordia RK, Scherer GW (1988) On constrained sintering. I. Constitutive model for a sintering body. Acta Mater 36:2393–2397

    Article  Google Scholar 

  53. Scherer GW (1979) Sintering inhomogeneous glasses: application to optical waveguides. J Non-Cryst Solids 34:239–256

    Article  Google Scholar 

  54. Peterson A, Agren J (2004) Constitutive benhavior of WC–co materials with different grain size sintered under load. Acta Mater 52:1847–1858

    Article  Google Scholar 

  55. Olevsky EA, German RM, Upadhyaya A (2000) Effect of gravity on dimensional change during sintering- Π shape distortion. Acta Mater 48:1167–1180

    Article  Google Scholar 

  56. Loh NH, German RM (1996) Statistical analysis of shrinkage variation for powder injection molding. J Mater Process Technol 59:278–284

    Article  Google Scholar 

  57. German RM (1990) Powder injection molding. MPIF, Princeton

    Google Scholar 

  58. Henrich B, Wonisch A, Kraft T, Moseler M, Riedel H (2007) Simulations of the influence of rearrangement during sintering. Acta Mater 55:753–762

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. FEMTO-ST Institute, CNRS/UFC/ENSMM/UTBM, Department of Applied Mechanics, Université Bourgogne Franche-Comté, 25000, Besancon, France

    M. Sahli, H. Ou, J.-C. Gelin, T. Barrière & M. Assoul

  2. Mechanics Laboratory, Faculty of Engineering Sciences, University Mentouri, Constantine, Algeria

    M. Sahli

  3. Faculty of Science and Technology, University of Khenchela, Khenchela, Algeria

    B. Mamen

Authors
  1. M. Sahli
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. B. Mamen
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. H. Ou
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. J.-C. Gelin
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. T. Barrière
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. M. Assoul
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to M. Sahli.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sahli, M., Mamen, B., Ou, H. et al. Experimental analysis and numerical simulation of sintered micro-fluidic devices using powder hot embossing process. Int J Adv Manuf Technol 99, 1141–1154 (2018). https://doi.org/10.1007/s00170-018-2509-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2509-5

Keywords

Search

Navigation