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Ceramic Injection Molding (CIM)

CIM Technology Process

Ceramic injection molding (CIM) is a process which allows ceramics, shaping and manufacturing , geometrically complex parts in single operation and in high volume. The economic advantage in Ceramic injection molded parts lies in complexity and volume for small-size parts.

ETP has in-house ability to design and manufacture tooling that can hold both the requirements of the finished part and the potential complications of the subsequent manufacturing process, which is the most important element in the success of the process .

The sub-micron size ceramic powder is mixed with binders and additives (various thermoplastics, waxes, and other materials), resulting in a 'feedstock' capable of being granulated and then injection molded into single / multiple cavities forming a green component . The green components then pass through various processes like, debinding, sintering, and other secondary operations, resulting in a final desired shape.

Dimensional tolerances of +/-.003" per linear inch can be commonly attained , so as, far more closer restrictions on tolerance possibly can be attained with expert technical knowledge and experience in molding and sintering. MIM can produce parts where it is difficult, or even impossible, to efficiently manufacture an item through other means of fabrication.

Categories

CIM Technology Flow Chart

CIM Advantage

Parameter
MIM
Conventional PM
Machining
Investment Casting
Density
98%
88%
100%
98%
Tensile Strength
High
Low
High
High
Elongation
High
Low
High
High
Hardness
High
Low
High
High
Complexity
High
Low
High
Medium
Surface Finish
High
Medium
High
Medium
Production
High
High
Low
Medium
Range of Materials
High
High
High
Medium-High
Cost
High
Low
High
Medium

CIM Materials Properties

Properties Units Alumina(Al2O3) Zirconia(ZrO2) Silicon Carbide(SiC) Silicon
Nitride
Aluminium Nitride
(AlN )
Boron
Carbide
(B4C)
Machanable
Glass
Ceramics
(MACOR)
Graphite Quartz Sapphire
Porous
Al2O3
Mullite Al2O3
85%
Al2O3
92%
Al2O3
96%
Al2O3
99.5%
Al2O3
99.8%
Y2O3- ZrO2 (YPTZ) Y2O3- ZrO2
(YPTZ)
SSiC SiSiC RSiC HPSi3N4
Mechanical Density g/cm3   2.8 3.4 3.6 3.7 3.9 3.92 3.8~4.6 5.9~6.3 >3.1 >3.02 2.6~2.7 3.2 3.3 2.51 2.52 1.57~1.88 2.2 3.97
Color _ _ Tan White White White Ivory Ivory White Ivory/White Black Black Gray Gray Gray Black White Black White White/Transpare
Water nt
Absorption
%   0 0 0 0 0 0 0 0 0 0 16 0 0 0 _ 0.3~3.0 0 0
Vickers
Hardness
Gpa _ 7.4 9.5 11 11.5 14 14~15 10.4~14.4 12.7 24 23.5 _ 14 10.5~11.5 3200× 230× 7~7.5 11.5~13.5 11.5~13.5
Flexural
Strength
(20°C)
Mpa 50~100 170 300 345 358 380 400 172~450 900 480 460 >100 700~800 260 400 94 50 80 760~1050
Compressiv
e Strength
(20°C)
Mpa 20~100 550 1950 2200 2300 3000 3150 2300~2900 2500 3200 2500 _ 3200 _ 3200 345 100~200 650~1100 2000
Thermal Thermal
Conductivity
(20°C)
W/m.K 3.1 3.5 16 16.7 24.8 25~35 30 13~27 2.2 150 125 24 26~42 ≥170 90 1.71 95 1.4 40
Thermal
Shock
Resistance
(20°C)
△T(C) _ 300 300 250 250 200 200 300~500 350 300 400 _ 530~610 400 _ _ 200~250 _ _
Maximum
Use
°C 1900 1700 1400 1500 1600 1700 1700 1400~1500 1500 1600 1380 1650 1400 1600 2450 800 _ 1200 2000
Electrical Volume
Resistivity
(25°C)
Ω.cm _ >1014 >1014 >1014 >1014 >1014 >1014 >1014 >1014 5×107 1 _ >1012 >1014 10 1014 0.3~1.0×10-3 7×107 >1016

CIM Materials and Applications

Materials 
材料 
Properties 
属性 
Some applications 
应用
     
SiC    
Silicon Carbide
碳化硅
Wear resistant
耐磨
Sliding bearings (SiC on Sic) )
滑动轴承
  Excellent chemical resistance
优良的耐化学性
Mechanical seals 
机械密封                                                                                            
  Good thermal shock resistance
抗热震性好缸 。 
Cylinders
圆柱体
  Low density 
低密度
Plungers
柱塞 
    Blast nozzles 
喷嘴
    Crucibles 
坩埚
Si3N4    
Silicon Nitride
碳化硅
Wear resistant 
耐磨
Ball bearings 
球轴承
  High strength, toughness
高强度,高韧性
Dies
切割
  Good thermal shock resistance 
  良好的抗热震
Valves  
阀门
  Chemical resistant
耐化学腐蚀
Crucibles
坩埚 
  Electrically insulating or conductive (special) 
电绝缘或导电(特殊)
Thermocouple tubes 
热双管
B4C    
Boron Carbide
碳化硼
Very hard 
硬质
Spray drying and powder blast nozzles 
喷雾干燥粉末喷嘴
  Wear resistant
耐磨
Dies 
切割
    Heavy-duty armour plate 
重型装甲板
    Lapping and polishing powders
研磨和抛光粉
BN    
Boron Nitride 
碳化硼
Relatively soft 
相对较软的
Crucibles 
坩埚
  Good machinable 
好加工
High-voltage insulators 
高压绝缘
  Is not wetted by liquid metals
  液态金属不湿 。
High-temperature lubricant and positioning tools
高温润滑和定位
  Electrical insulator 
点绝缘
 
ALN    
Aluminium Nitride
碳化铝
Good heat conductivity
良好的热传导性
Heat Sinks 
染热
  Chemical resistant  
耐化学腐蚀 
Substrates 
基板
ZrO2    
Zirconia 
氧化锆
Impact resistant 
耐冲击
Welding pins 
焊接引脚
  Heat insulator 
热绝缘
Positioning tools 
定位工具
  High strength and toughness
高强度和韧性
Machine components
机组件
AI2O3    
Alumina 
氧化铝
Electrical insulator 
电绝缘
Components for furnaces 
炼炉组件 
  Wear resistant 
耐磨
Thermocouple tubes
高温双管
  Resistant to high temperatures
耐高温
Machine components 
机组件
     
Ruby 
红宝石色
High surface quality
高处理质量
Precision balls 0.1 micron tolerance
精密球0.1微米公差
  Chemical resistant 
耐化学组件
Ball valves up to 1,000 bar 
球阀1000
Sapphire
天蓝色
Transparent 
透明
Optical precision components
光学精密组件

Machining Capability

Item Machining Process Working Range /Table Loading 
最大加工范围及加工重量
Machining Accuracy ( mm )
项目 加工方式 加工精度(所有尺寸mm)
  加工范围
(XxYxZ)mm
加工重 Kg Hole Dia Tolerance
孔径公差 
  (孔Ø2~50时)
Circularity / Cylindricity
孔圆度 / 圆柱度      
     (孔Ø2~50 时)
Hole Distance
孔间距B  / 孔边距A公差 
      A or B ≤ 75时
Hole Perpendicularity 
孔轴线  
 [ ⊥ ]    孔深 T≤15 时
Hole  Parallelism 孔轴线 [ ∥ ]   孔深 T≤15 时    Surface roughness 表面粗糙度    Ra(μm)   
                 
1 Milling Machining
普通铣削加工 
914*406*406 700  ≥ ± 0.01 0.01~0.03  ≥ ± 0.02 0.01~0.03 0.01~0.03 1.6~3.2  
2 High Speed Milliing Machining
高速CNC铣削加工 
800 * 500 400  ≥ ± 0.005 0.008~0.02  ≥ ± 0.01 0.008~0.02 0.008~0.02 0.8~1.6  
3 Wire Cut W/C 
放电加工   
350 * 250 200  ≥ ± 0.0025 0.0025~0.005  ≥ ± 0.0025 0.0025~0.005 0.0025~0.005 0.2~0.4  
                 
    Hole Dia Tolerance
孔径公差 
     (Ø  1.0 ~ 50; L ≤ 50 时)
Plane  Tolerance
平面度 
     (≤75x75; T ≥ 3.0 时)
Perpendicularity 
垂直度
 [ ⊥ ]    ≤75x75时
Parallelism 
平行度
  [ ∥ ]   ≤75x75,T≥3.0时
Circularity / Cylindricity
孔圆度 / 圆柱度 
  (孔Ø2~50 时, L ≤ 50 时)
Concentricity
同轴度     
  (孔Ø2~50 时, L ≤ 50 时)
Surface roughness
表面粗糙度  
   Ra(μm)   
  Turning
普通车床   
Max:Dia.     Ø 300 750  ≥ ± 0.01  --  --  -- 0.01~0.02 0.01~0.02 0.8~1.6
  Min:Dia.      Ø 0.50 10
  Precision Surface Grinding Machine
平面磨床 
370x160 75kg  -- 0.005~0.01 0.005~0.01 0.005~0.01  --  -- 0.2~0.4
  Single Lappping Machine
单面研磨机  
Max Ø130  Thickness: 1~50  -- 0.005~0.01  -- 0.005~0.01  --  -- 0.05~0.2
  Max Ø130  厚度 1~50

Inspection Equipment

Department: Inspection Instrument ( Production Equipment Total List ) NO:006
S.No.
Equipment Name
Machine Number
Quantity
Remarks
1.
Height Gauge
ETM001
1
2.
Micro scope
ETM002
1
With Optics Ruler
3.
Gauge Block
ETM003
1
Including optics ruler,and Disk
4.
Digital Calliper
ETM004
1
5.
Profile Projector
ETM005
1
optics ruler, detailed listing floppy disk
6.
Pin Gauge
ETM006
1
7.
Micrometer
ETM007 - ETM008
2
Optics ruler
8.
Micro-Dial-Indicaor
ETM009
1
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