黃坤祥臺灣大學：材料科學與工程學研究所王鴻儒2007-11-262018-06-282007-11-262018-06-282005http://ntur.lib.ntu.edu.tw//handle/246246/55184金屬粉末經壓製或射出後必須經燒結才有足夠之機械性質，但在未燒結前必須具備一相當之強度，以應付搬運過程中工件彼此間以及與外物碰撞所遭受之應力。因此，本實驗的主要目的即是藉由調整黏結劑配方及製程參數探討其對射出成形元件生胚強度的影響。 在粉末射出成形中一般都使用聚丙烯或聚乙烯來當做骨架黏結劑，本實驗比較不同聚丙烯和聚乙烯胚料的黏度及生胚強度作為評論的標準，由結果顯示，聚乙烯的胚料在各製程中都能有效的控制，且具有好的黏度及生胚強度，聚乙烯的效果遠比聚丙烯來得佳。高溫石蠟並不能如所期待地減少生胚的收縮量。另外，Mg-St和Li-St的添加雖可改善射出品質，但並沒有預期的強化效果，反而使拉伸強度明顯的下降。 在溶劑脫脂的階段，試片的尺寸變化之結果顯示，試片在脫脂時會產生膨脹的現象，此乃因溫度差異造成的熱膨脹及黏結劑在溶劑中的膨潤反應所造成。此外，黏結劑脫脂溫度、黏結劑含量及黏結劑的種類都會影響溶脫時的膨脹量。　　Metal powder compacts and metal injection molded(MIM) parts are usually fragile before sintering. This low strength caused damages during handling. For this reason, the objective of this study was to examine the effects of binder selection and molding parameters on the green strength of MIM parts. 　　Polypropylene and polyethylene were generally used as the backbone binder in MIM. Thus, various PP and PE were examined for their advantages and disadvantages. The results show that PE is better than PP. High Temperature Paraffin Wax(HTPW) was examined, but no advantages. Addition of the Mg-St and Li-St can improve quality of molding, but no important in strengthen. 　　During the solvent debinding, swelling was observed when the spec- imens were immersed in the solvent. The major causes were the thermal expansion due to the temperature rise of the specimens and the swelling reaction between the binder and solvent. The amount of expansion was also related to the temperature, amount of the binder, and the type of the binder selected.摘要.....................................................ii Abstract................................................iii 目錄.....................................................iv 圖目錄...................................................xi 表目錄................................................xviii 第一章 簡介...............................................1 第二章 文獻回顧...........................................3 2-1 射料的準備............................................3 2-1-1 粉末性質............................................4 2-1-2 黏結劑性質..........................................5 2-1-3 射料的混煉均勻性....................................8 2-1-4 回收射料的效應......................................8 2-2 射出成形..............................................9 2-2-1 成形時的缺陷成因....................................9 2-2-1-1 短射.............................................10 2-2-1-2 融合線...........................................10 2-2-1-3 破裂與殘留應力...................................10 2-2-1-4 收縮孔...........................................13 2-2-1-5 頂出缺陷.........................................14 2-2-1-6 延遲破壞.........................................15 2-2-1-7 粉體與黏結劑的分離現象...........................15 2-2-1-8 噴流現象.........................................16 2-2-2 製程最佳化與品質控制...............................18 2-3 脫脂.................................................18 2-3-1 溶劑脫脂...........................................20 2-3-2 熱脫脂.............................................22 2-3-3 真空脫脂...........................................22 2-4 燒結.................................................23 2-5 研究目的.............................................24 第三章 實驗..............................................25 3-1 實驗設計.............................................25 3-2 原料.................................................25 3-2-1 基礎粉.............................................25 3-2-2 其他粉末...........................................27 3-2-3 黏結劑.............................................29 3-3 球磨.................................................30 3-4 混合.................................................30 3-5 混煉.................................................31 3-6 射出成形.............................................32 3-7 烘烤.................................................36 3-8 脫脂.................................................37 3-8-1 溶劑脫脂...........................................37 3-8-2 真空脫脂...........................................38 3-9 燒結.................................................38 3-10 性質測試............................................39 3-10-1 黏度測試..........................................39 3-10-2 生胚強度測試......................................41 3-10-3 密度測試..........................................41 3-10-4 拉伸強度測試......................................42 3-10-5 雷射膨脹儀........................................43 3-10-6 測量值穩定性的評估................................45 3-11 實驗儀器............................................45 第四章 結果與討論........................................47 4-1 粉末種類的影響.......................................47 4-1-1 羰基鐵粉和不銹鋼粉的溶脫行為.......................47 4-2 黏結劑的比較.........................................49 4-2-1 骨架結劑系列.......................................49 4-2-1-1 粉末與生胚形狀的選擇.............................50 4-2-1-2 示差分析(DSC)測試................................50 4-2-1-3 熱重分析(TGA)測試................................53 4-2-1-4 溶脫測試.........................................56 4-2-1-5 胚料的黏度測試...................................57 4-2-1-6 流動性測試.......................................60 4-2-1-7 試片的尺寸及密度.................................61 4-2-1-8 燒結試片的硬度...................................62 4-2-1-9 試片的生胚強度...................................62 4-2-1-10 拉伸強度........................................64 4-2-2 填充劑系列.........................................66 4-2-2-1 粉末與生胚形狀的選擇.............................66 4-2-2-2 示差分析(DSC)測試................................66 4-2-2-3 熱重分析(TGA)測試................................67 4-2-2-4 黏結劑的密度比較.................................69 4-2-2-5 胚料的黏度測試...................................69 4-2-2-6 拉伸強度.........................................71 4-2-3 潤滑劑與界面活性劑系列.............................72 4-2-3-1 粉末與生胚形狀的選擇.............................73 4-2-3-2 示差分析(DSC)測試................................74 4-2-3-3 熱重分析(TGA)測試................................75 4-2-3-4 溶脫曲線.........................................77 4-2-3-5 胚料黏度測試.....................................78 4-2-3-6 流動性測試(Spiral Test)..........................80 4-2-3-7 生胚強度測試.....................................82 4-2-3-8 試片的密度.......................................83 4-2-3-9 燒結試片的硬度...................................83 4-2-3-10 拉伸強度........................................84 4-2-4 特殊型黏結劑.......................................87 4-2-4-1 溶脫測試.........................................87 4-2-4-2 示差分析(DSC)測試................................87 4-2-4-3 熱重分析(TGA)測試................................88 4-2-4-4 混煉方式.........................................90 4-2-4-5 黏度測試.........................................90 4-2-4-6 生胚強度測試.....................................91 4-3 混煉的影響...........................................92 4-3-1 混煉方式對生胚強度的影響...........................92 4-3-2 混煉方式對黏度的影響...............................94 4-3-3 混煉方式對射壓的影響...............................95 4-4 射出參數的影響.......................................96 4-4-1 射壓與轉壓點的關係.................................96 4-4-2 黏結劑種類對射壓的影響.............................97 4-4-3 射壓高低對溶脫時尺寸變化的關係.....................98 4-4-4 射壓對尺寸的影響...................................99 4-4-5 射速與生胚強度的關係..............................100 4-4-6 射速與生胚密度的關係..............................101 4-4-7 轉壓點對生胚強度的影響............................102 4-4-8 保壓對生胚強度的影響..............................103 4-4-9 保壓對射壓的影響..................................105 4-5 烘烤的影響..........................................106 4-5-1 烘烤對生胚強度的影響..............................106 4-5-2 烘烤對生胚尺寸的影響..............................107 4-6 溶劑脫脂的影響......................................107 4-6-1 生胚脫脂現象的探討................................108 4-6-2 溶脫時的缺陷......................................116 4-6-3 黏結劑與溶脫時尺寸變化的關係......................119 第五章 結論.............................................122 第六章 建議.............................................124 第七章 未來工作.........................................126 參考文獻................................................1274239703 bytesapplication/pdfen-US粉末射出成形生胚強度毛細流變脫脂膨脹儀Powder injection molding (PIM)green strengthcapillary rheologydebindingswelling dilatometerthesishttp://ntur.lib.ntu.edu.tw/bitstream/246246/55184/1/ntu-94-R92527060-1.pdf