Optimization of the Sintering Parameters for Materials Manufactured by Powder Injection Molding

The properties of sintered and heat-treated steels produced from the Catamold 8740 material by powder injection molding were examined. Parts made of the Catamold 8740 low-alloy mild carbon steel are used in the military, automotive, and other industries where high reliability and resistance to dynamic loads are required. The Catamold 8740 chemical homogeneity was studied as a function of powder injection molding parameters: heating rate, sintering temperature, holding time, and subsequent heat treatment. Microscopic analysis showed that Catamold 8740 was a mechanical mixture of powders in various sizes (carbonyl iron, nickel, Fe–Mo, Fe–Cr, Fe–Si-Mo, Fe–Si). When the heating rate of the Catamold 8740 powder mixture increased from 2 to 5 °C/min, the microstructural heterogeneity caused by uneven compaction decreased and the alloy formation process activated at 900–1340°C. The impact strength of Charpy V-notch test samples changed from 10.39 to 11.52 J/cm² with higher sintering temperature and heating rate increasing from 2 °C/min (1270°C) to 5 °C/min (1340°C). When holding time increased from 30 to 90 min at a sintering temperature of 1340°C, the material became denser, the pores rounded, and the ferrite matrix homogeneous. However, the impact strength decreased by a factor of 1.4 because of coarser grain sizes and brittle fracture. Heat treatment processes reduced the impact strength after sintering. The results obtained were used to optimize the powder injection molding parameters. The influence of chemical and dimensional inhomogeneity of the starting Catamold 8740 powders and sintering kinetics on the structure and mechanical properties of parts operating under impact loads was established.