Micro-Injection Molding and Debinding Behavior of Hydroxyapatite/Zirconia Bi-Materials Fabricated by Two-Component Micro-Powder Injection Molding Process
The micro-scale joining of two different materials using two-component micro-powder injection molding (2C-µPIM) is an intriguing technique. The formation of defects in bi-materials at different processing stages makes this technique challenging. This study presents the fabrication of defect-free bi-...
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MDPI AG
2023-09-01
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| Online Access: | https://www.mdpi.com/1996-1944/16/19/6375 |
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| author | Al Basir Norhamidi Muhamad Abu Bakar Sulong Muhammad bin Mohamed Amin Nashrah Hani Jamadon Nabilah Afiqah Mohd Radzuan |
| author_facet | Al Basir Norhamidi Muhamad Abu Bakar Sulong Muhammad bin Mohamed Amin Nashrah Hani Jamadon Nabilah Afiqah Mohd Radzuan |
| author_sort | Al Basir |
| collection | DOAJ |
| description | The micro-scale joining of two different materials using two-component micro-powder injection molding (2C-µPIM) is an intriguing technique. The formation of defects in bi-materials at different processing stages makes this technique challenging. This study presents the fabrication of defect-free bi-material micro-parts containing hydroxyapatite (HA) and 3 mol% yttria-stabilized zirconia (3YSZ) via 2C-µPIM. Critical powder volume concentrations (CPVCs) of 61.7 vol% and 47.1 vol% were obtained for the HA and 3YSZ powders, respectively. Based on the CPVCs, the optimal loadings for the HA and 3YSZ powders were selected as 60 vol% and 45 vol%, respectively. The HA and 3YSZ feedstocks were prepared by separately mixing the optimal powder contents with low-density polyethylene (LDPE) and palm stearin binders. The feedstocks displayed pseudoplastic behavior, and the lowest ranges of viscosity for the HA and 3YSZ at a temperature of 180 °C were 157.1–1392.5 Pa·s and 726.2–985.5 Pa·s, respectively. The feedstocks were injected to produce green HA/3YSZ micro-sized components. It was found that a solvent debinding temperature of 70 °C removed 60.6% of the palm stearin binder from the sample. In the thermal debinding stage, the open channels that formed in the bi-material sample’s solvent debound at 70 °C and contributed to the removal of 93 to 95% of the binder system. When the debound bi-materials were sintered at 1300 °C, the highest relative density of 96.3% was obtained. The sintering operation revealed a linear shrinkage between 13 and 17% in the sintered HA/3YSZ micro-parts. |
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| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T21:41:49Z |
| publishDate | 2023-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-7cf0094ddc6344458dcf05b66063eb9f2023-11-19T14:39:01ZengMDPI AGMaterials1996-19442023-09-011619637510.3390/ma16196375Micro-Injection Molding and Debinding Behavior of Hydroxyapatite/Zirconia Bi-Materials Fabricated by Two-Component Micro-Powder Injection Molding ProcessAl Basir0Norhamidi Muhamad1Abu Bakar Sulong2Muhammad bin Mohamed Amin3Nashrah Hani Jamadon4Nabilah Afiqah Mohd Radzuan5Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, MalaysiaDepartment of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, MalaysiaDepartment of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, MalaysiaDepartment of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, MalaysiaDepartment of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, MalaysiaDepartment of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, MalaysiaThe micro-scale joining of two different materials using two-component micro-powder injection molding (2C-µPIM) is an intriguing technique. The formation of defects in bi-materials at different processing stages makes this technique challenging. This study presents the fabrication of defect-free bi-material micro-parts containing hydroxyapatite (HA) and 3 mol% yttria-stabilized zirconia (3YSZ) via 2C-µPIM. Critical powder volume concentrations (CPVCs) of 61.7 vol% and 47.1 vol% were obtained for the HA and 3YSZ powders, respectively. Based on the CPVCs, the optimal loadings for the HA and 3YSZ powders were selected as 60 vol% and 45 vol%, respectively. The HA and 3YSZ feedstocks were prepared by separately mixing the optimal powder contents with low-density polyethylene (LDPE) and palm stearin binders. The feedstocks displayed pseudoplastic behavior, and the lowest ranges of viscosity for the HA and 3YSZ at a temperature of 180 °C were 157.1–1392.5 Pa·s and 726.2–985.5 Pa·s, respectively. The feedstocks were injected to produce green HA/3YSZ micro-sized components. It was found that a solvent debinding temperature of 70 °C removed 60.6% of the palm stearin binder from the sample. In the thermal debinding stage, the open channels that formed in the bi-material sample’s solvent debound at 70 °C and contributed to the removal of 93 to 95% of the binder system. When the debound bi-materials were sintered at 1300 °C, the highest relative density of 96.3% was obtained. The sintering operation revealed a linear shrinkage between 13 and 17% in the sintered HA/3YSZ micro-parts.https://www.mdpi.com/1996-1944/16/19/6375two-component micro-powder injection moldingHA/3YSZ micro-partsfeedstocksolvent debindingthermal debinding |
| spellingShingle | Al Basir Norhamidi Muhamad Abu Bakar Sulong Muhammad bin Mohamed Amin Nashrah Hani Jamadon Nabilah Afiqah Mohd Radzuan Micro-Injection Molding and Debinding Behavior of Hydroxyapatite/Zirconia Bi-Materials Fabricated by Two-Component Micro-Powder Injection Molding Process Materials two-component micro-powder injection molding HA/3YSZ micro-parts feedstock solvent debinding thermal debinding |
| title | Micro-Injection Molding and Debinding Behavior of Hydroxyapatite/Zirconia Bi-Materials Fabricated by Two-Component Micro-Powder Injection Molding Process |
| title_full | Micro-Injection Molding and Debinding Behavior of Hydroxyapatite/Zirconia Bi-Materials Fabricated by Two-Component Micro-Powder Injection Molding Process |
| title_fullStr | Micro-Injection Molding and Debinding Behavior of Hydroxyapatite/Zirconia Bi-Materials Fabricated by Two-Component Micro-Powder Injection Molding Process |
| title_full_unstemmed | Micro-Injection Molding and Debinding Behavior of Hydroxyapatite/Zirconia Bi-Materials Fabricated by Two-Component Micro-Powder Injection Molding Process |
| title_short | Micro-Injection Molding and Debinding Behavior of Hydroxyapatite/Zirconia Bi-Materials Fabricated by Two-Component Micro-Powder Injection Molding Process |
| title_sort | micro injection molding and debinding behavior of hydroxyapatite zirconia bi materials fabricated by two component micro powder injection molding process |
| topic | two-component micro-powder injection molding HA/3YSZ micro-parts feedstock solvent debinding thermal debinding |
| url | https://www.mdpi.com/1996-1944/16/19/6375 |
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