Advertisement

Journal of Advanced Ceramics

, Volume 5, Issue 4, pp 321–328 | Cite as

Effects of different backbone binders on the characteristics of zirconia parts using wax-based binder system via ceramic injection molding

  • Jiaxin Wen
  • Zhipeng Xie
  • Wenbin Cao
  • Xianfeng Yang
Open Access
Research Article

Abstract

In this work, various backbone binders were used in wax-based binder system to formulate zirconia parts by ceramic injection molding (CIM). The effect of different backbone binders on the molding, debinding, and sintering behaviors was investigated. After blending process, the feedstock using multi-polymer components exhibited more homogeneous structure compared with that using the mono-polymer ones due to the synergistic effect of multi-polymers. During solvent debinding, some defects such as “slumping” and “peeling” appeared in the parts containing ethylene-vinyl acetate copolymer (EVA), but they were not found in the parts with other thermal polymers. Also, as for the parts after sintering, the one using low density polyethylene (LDPE) and high density polyethylene (HDPE) as backbone binders presented a more uniform microstructure with finer zirconia grains among all the investigated compositions, and thus obtained the highest flexural strength (~949 MPa) and relative density (~98.9%).

Keywords

ceramic injection molding (CIM) ZrO2 backbone binders solvent debinding sintering 

Notes

Acknowledgements

This work was financially supported by National Natural Science Foundation of China (Grant No. 51572035).

References

  1. [1]
    Mutsuddy BC, Ford RG. Ceramic Injection Molding. London: Chapman & Hall, 1995: 1–22.Google Scholar
  2. [2]
    German RM. Powder Metallurgy Science, 2nd edn. Princeton, NJ, USA: MPIF, 1994.Google Scholar
  3. [3]
    German RM. Powder Injection Molding. Princeton, NJ, USA: MPIF, 1990.Google Scholar
  4. [4]
    Lin ST, German RM. Interaction between binder and powder in injection molding of alumina. J Mater Sci 1994, 29: 5207–5212.CrossRefGoogle Scholar
  5. [5]
    Liu D-M, Tseng WJ. Yield behavior of zirconia-wax suspensions. Mat Sci Eng A 1998, 254: 136–146.CrossRefGoogle Scholar
  6. [6]
    Trunec M, Cihlar J. Thermal removal of multicomponent binder from ceramic injection moldings. J Eur Ceram Soc 2002, 22: 2231–2241.CrossRefGoogle Scholar
  7. [7]
    Zhang T, Evans JRG. Relaxation effects in large injection molded ceramic bodies. J Eur Ceram Soc 1993, 12: 51–59.CrossRefGoogle Scholar
  8. [8]
    Yang S, Zhang R, Qu X. X-ray analysis of powder-binder separation during SiC injection process in L-shaped mould. J Eur Ceram Soc 2015, 35: 61–67.CrossRefGoogle Scholar
  9. [9]
    Thomas-Vielma P, Cervera A, Levenfeld B, et al. Production of alumina parts by powder injection molding with a binder system based on high density polyethylene. J Eur Ceram Soc 2008, 28: 763–771.CrossRefGoogle Scholar
  10. [10]
    Liu ZY, Loh NH, Tor SB, et al. Binder system for micropowder injection molding. Mater Lett 2001, 48: 31–38.CrossRefGoogle Scholar
  11. [11]
    Yang W-W, Yang K-Y, Wang M-C, et al. Solvent debinding mechanism for alumina injection molded compacts with water-soluble binders. Ceram Int 2003, 29: 745–756.CrossRefGoogle Scholar
  12. [12]
    Liu W, Xie Z, Zhang L, et al. Debinding behaviors and mechanism of injection molded ZrO2 ceramics using kerosene as solvents. Key Eng Mater 2012, 512–515: 431–434.CrossRefGoogle Scholar
  13. [13]
    Matula G, Dobrzanski LA, Varez A, et al. Development of a feedstock formulation based on PP for MIM of carbides reinforced M2. Journal of Achievements in Materials and Manufacturing Engineering 2008, 27: 195–198.Google Scholar
  14. [14]
    Islam SH, Qu XH, Tufai M. Preparation and characterization of tungsten heavy alloy feedstock for metal injection molding. Adv Mater Res 2007, 26–28: 363–366.CrossRefGoogle Scholar
  15. [15]
    Kim SW, Lee H-W, Song H. Effect of minor binder on capillary structure evolution during wicking. Ceram Int 1999, 25: 671–676.CrossRefGoogle Scholar
  16. [16]
    Setasuwon P, Bunchavimonchet A, Danchaivijit S. The effects of binder components in wax/oil systems for metal injection molding. J Mater Process Tech 2008, 196: 94–100.CrossRefGoogle Scholar
  17. [17]
    Ani SM, Muchtar A, Muhamad N, et al. Binder removal via a two-stage debinding process for ceramic injection molding parts. Ceram Int 2014, 40: 2819–2824.CrossRefGoogle Scholar
  18. [18]
    Supati R, Loh NH, Khor KA, et al. Mixing and characterization of feedstock for powder injection molding. Mater Lett 2000, 46: 109–114.CrossRefGoogle Scholar
  19. [19]
    González-Gutiérrez J, Stringari G, Emri I. Powder injection molding of metal and ceramic parts. In Some Critical Issues for Injection Molding. Wang J, Ed. InTech, 2012: 65–88.Google Scholar
  20. [20]
    Hidalgo J, Abajo C, Jiménez-Morales A, et al. Effect of a binder system on the low-pressure powder injection moulding of water-soluble zircon feedstocks. J Eur Ceram Soc 2013, 33: 3185–3194.CrossRefGoogle Scholar
  21. [21]
    Li S, Huang B, Li Y, et al. A new type of binder for metal injection molding. J Mater Process Tech 2003, 127: 70–73.CrossRefGoogle Scholar
  22. [22]
    Zaky MT, Soliman FS, Farag AS. Influence of paraffin wax characteristics on the formulation of wax-based binders and their debinding from green molded parts using two comparative techniques. J Mater Process Tech 2009, 209: 5981–5989.CrossRefGoogle Scholar
  23. [23]
    Goodship V. Practical Guide to Injection Moulding. Shawbury, UK: Rapra Technology, 2004.Google Scholar
  24. [24]
    Lee S-Y. Sintering behavior and mechanical properties of injection-molded zirconia powder. Ceram Int 2004, 30: 579–584.CrossRefGoogle Scholar

Copyright information

© The Author(s) 2016

Open Access The articles published in this journal are distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.

Authors and Affiliations

  • Jiaxin Wen
    • 1
  • Zhipeng Xie
    • 2
  • Wenbin Cao
    • 1
  • Xianfeng Yang
    • 3
  1. 1.School of Materials Science and EngineeringUniversity of Science and Technology BeijingBeijingChina
  2. 2.State Key Laboratory of New Ceramics and Fine Processing, Department of Materials Science and EngineeringTsinghua UniversityBeijingChina
  3. 3.College of Physics and Electronics ScienceChangsha University of Science & TechnologyChangshaChina

Personalised recommendations