Moldflow Simulation and Characterization of Pure Copper Fabricated via Metal Injection Molding
Metal injection molding (MIM) is a representative near-net-shape manufacturing process that fabricates advanced geometrical components for automobile and device industries. As the mechanical performance of an MIM product is affected by green-part characteristics, this work investigated the green par...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-07-01
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| Online Access: | https://www.mdpi.com/1996-1944/16/15/5252 |
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| author | Warda Bahanan Siti Fatimah Hyunseok Song Eun Hye Lee Dong-Ju Kim Hae Woong Yang Chang Hoon Woo Jungho Ryu I Putu Widiantara Young Gun Ko |
| author_facet | Warda Bahanan Siti Fatimah Hyunseok Song Eun Hye Lee Dong-Ju Kim Hae Woong Yang Chang Hoon Woo Jungho Ryu I Putu Widiantara Young Gun Ko |
| author_sort | Warda Bahanan |
| collection | DOAJ |
| description | Metal injection molding (MIM) is a representative near-net-shape manufacturing process that fabricates advanced geometrical components for automobile and device industries. As the mechanical performance of an MIM product is affected by green-part characteristics, this work investigated the green part of pure copper processed with MIM using the injection temperature of ~180 °C and injection pressure of ~5 MPa. A computational analysis based on the Moldflow program was proposed to simulate the effectivity of the process by evaluating the confidence of fill, quality prediction, and pressure drop of three distinctive regions in the green part. The results showed that the ring and edge regions of the green parts showed localized behavior, which was related to processing parameters including the position of the gate. A microstructural observation using scanning electron microscopy and a 3D X-ray revealed that both the surface and body matrix consisted of pores with some agglomeration of micro-pores on the edges and ring part, while any critical defects, such as a crack, were not found. A microhardness analysis showed that the three regions exhibited a reasonable uniformity with a slight difference in one specific part mainly due to the localized pore agglomeration. The simulation results showed a good agreement with the microstructures and microhardness data. Thus, the present results are useful for providing guidelines for the sound condition of MIM-treated pure copper with a complex shape. |
| first_indexed | 2024-03-11T00:23:42Z |
| format | Article |
| id | doaj.art-b1414f0acada461fa444ff62bf2998eb |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-11T00:23:42Z |
| publishDate | 2023-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-b1414f0acada461fa444ff62bf2998eb2023-11-18T23:10:57ZengMDPI AGMaterials1996-19442023-07-011615525210.3390/ma16155252Moldflow Simulation and Characterization of Pure Copper Fabricated via Metal Injection MoldingWarda Bahanan0Siti Fatimah1Hyunseok Song2Eun Hye Lee3Dong-Ju Kim4Hae Woong Yang5Chang Hoon Woo6Jungho Ryu7I Putu Widiantara8Young Gun Ko9School of Materials Science and Engineering, Yeungnam University, Gyeongsan 38541, Republic of KoreaSchool of Materials Science and Engineering, Yeungnam University, Gyeongsan 38541, Republic of KoreaSchool of Materials Science and Engineering, Yeungnam University, Gyeongsan 38541, Republic of KoreaKyerim Metal Co., Ltd., Chilgok 39910, Republic of KoreaSeA Mechanics Co., Ltd., Gumi 39379, Republic of KoreaPohang Institute of Metal Industry Advancement, Pohang 37666, Republic of KoreaKyerim Metal Co., Ltd., Chilgok 39910, Republic of KoreaSchool of Materials Science and Engineering, Yeungnam University, Gyeongsan 38541, Republic of KoreaSchool of Materials Science and Engineering, Yeungnam University, Gyeongsan 38541, Republic of KoreaSchool of Materials Science and Engineering, Yeungnam University, Gyeongsan 38541, Republic of KoreaMetal injection molding (MIM) is a representative near-net-shape manufacturing process that fabricates advanced geometrical components for automobile and device industries. As the mechanical performance of an MIM product is affected by green-part characteristics, this work investigated the green part of pure copper processed with MIM using the injection temperature of ~180 °C and injection pressure of ~5 MPa. A computational analysis based on the Moldflow program was proposed to simulate the effectivity of the process by evaluating the confidence of fill, quality prediction, and pressure drop of three distinctive regions in the green part. The results showed that the ring and edge regions of the green parts showed localized behavior, which was related to processing parameters including the position of the gate. A microstructural observation using scanning electron microscopy and a 3D X-ray revealed that both the surface and body matrix consisted of pores with some agglomeration of micro-pores on the edges and ring part, while any critical defects, such as a crack, were not found. A microhardness analysis showed that the three regions exhibited a reasonable uniformity with a slight difference in one specific part mainly due to the localized pore agglomeration. The simulation results showed a good agreement with the microstructures and microhardness data. Thus, the present results are useful for providing guidelines for the sound condition of MIM-treated pure copper with a complex shape.https://www.mdpi.com/1996-1944/16/15/5252coppermetal injection moldingmoldflowgreen part |
| spellingShingle | Warda Bahanan Siti Fatimah Hyunseok Song Eun Hye Lee Dong-Ju Kim Hae Woong Yang Chang Hoon Woo Jungho Ryu I Putu Widiantara Young Gun Ko Moldflow Simulation and Characterization of Pure Copper Fabricated via Metal Injection Molding Materials copper metal injection molding moldflow green part |
| title | Moldflow Simulation and Characterization of Pure Copper Fabricated via Metal Injection Molding |
| title_full | Moldflow Simulation and Characterization of Pure Copper Fabricated via Metal Injection Molding |
| title_fullStr | Moldflow Simulation and Characterization of Pure Copper Fabricated via Metal Injection Molding |
| title_full_unstemmed | Moldflow Simulation and Characterization of Pure Copper Fabricated via Metal Injection Molding |
| title_short | Moldflow Simulation and Characterization of Pure Copper Fabricated via Metal Injection Molding |
| title_sort | moldflow simulation and characterization of pure copper fabricated via metal injection molding |
| topic | copper metal injection molding moldflow green part |
| url | https://www.mdpi.com/1996-1944/16/15/5252 |
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