Powder Metal Parts and Powder Metallurgy Process Overview
Powder metals are alloys that are processed into fine, granular powders through one of a variety of processes. These metals are primarily made of stainless steel, brass, copper, iron, or bronze and can be blended with other alloys to achieve the material properties and characteristics required for a specific application. Powder metal parts offer greater flexibility in material use and mechanical properties, can be highly customized and easily replicated, while producing high-strength, cost-effective components.
Making High-Strength Components
Powder metallurgy (PM) refers to a manufacturing process that forms powdered metal or metal mixtures into desired specifications through a unique combination of heat and compression, resulting in parts and components that are stronger than traditional forging processes.
The process is shorter than other manufacturing techniques, and the main steps include the following:
1. The metal is made into powder through chemical treatments such as solid-state reduction, atomization, electrolysis, or oxide reduction and thermal decomposition.
2. The powder is mixed with other metals, alloying agents, and lubricants to reduce friction, increase flow, and produce a homogenous mixture, which is then fed into a rigid tooling set for processing.
3. The metal mixture is compressed into the appropriate geometry using dies, punches, hydraulic presses, or other consolidation measures.
4. The compacted fragments are sintered in a controlled atmosphere, using extremely high temperatures to metallurgically bond the particles.
5. Secondary operations are performed on the parts, depending on the requirements of the end application.
The PM process is considered environmentally friendly because it produces harmless nitrogen and hydrogen byproducts, while also limiting production waste by utilizing more than 97% of the material entering the process.
Heat Treatment and Finishing Options
After sintering, parts may undergo additional heat treatment or finishing to increase material strength and hardness, improve corrosion resistance, improve part tolerances, enhance surface finish, etc.
Secondary operations include the following:
· Heat treatment: quenching, tempering, steam treatment, furnace welding, etc.
· Machining: drilling and tapping, turning, milling or grinding
· Impregnation: oil or resin
· Finishing: deburring, tumbling, polishing, coating or plating, welding, etc.
Shenzhen Yujiaxin Technology Co., Ltd. has been specializing in the field of metal powder metallurgy processing since its establishment, dedicating itself to the research and development of the entire chain technology including metal powder preparation, forming, sintering, and post-treatment. Leveraging advanced Metal Injection Molding (MIM), Powder Metallurgy Pressing (PM), and Powder Metallurgy Copper Infiltration techniques, the company provides high-precision, high-performance metal component solutions for various industries such as automotive, electronics, communications, and medical devices. Through continuous optimization of production processes, Yujiaxin Technology has significantly enhanced product density, hardness, and wear resistance, earning widespread recognition in the market.
5 New Innovative Medical Devices to Watch Out For!
From pulsed field ablation to diabetes and surgical robotics, there are many important medical devices being launched.
1. Pulsed Field Ablation
Device: Farapulse
The system was acquired by Boston Scientific in 2021 for nearly $300 million. The entire system includes the Farawave ablation catheter, Farastar ablation generator, and Faradrive steerable sheath, which together provide pulsed field energy. Farapulse uses non-thermal treatment technology to selectively ablate cardiac tissue through electric fields, and its catheter design is unique. It is an online catheter with a variable shape that can adapt to the pulmonary venous anatomy of different patients to achieve personalized treatment.
2. Tricuspid Valve Replacement
Device: Evoque Tricuspid
Evoque is a transcatheter therapy designed by Edwards Lifesciences specifically for the treatment of tricuspid regurgitation. The therapy received FDA approval in February, becoming the first FDA-approved transcatheter device for tricuspid regurgitation. Evoque features a nitinol self-expanding frame, annular skirt, and tissue leaflets made from bovine pericardial tissue.
3. Continuous Glucose Monitoring
Device: Non-insulin Designed CGM
Stelo CGM is a 15-day continuous glucose monitoring system designed by Dexcom, and the software experience is specifically customized for non-insulin dependent diabetics.
Shortly after Dexcom submitted its application to the FDA, company CEO Kevin Sayer told Drug Delivery Business News that Stelo CGM was designed with non-insulin users in mind and would not “bother” users with frequent alerts and reminders, but instead provide the personalized insights users need. As a result, Sayer noted that the company’s production line is ready for production. In addition, it is worth noting that Stelo CGM was not initially promoted as a cash payment option, but was acquired through an over-the-counter transaction in March.
4. Surgical Robotic Applications
Equipment: Mako Spine/Shoulder
Early last year, Stryker said that its Mako surgical robotic platform will achieve significant application expansion in 2024. Mako Spine is an application combined with the company’s new bone cutting product. And Mako Shoulder will use robotic applications to increase incremental precision.
In addition, Stryker will continue to expand the scope of Mako’s applications. Earlier this year, they launched a new medium to enhance the surgeon’s experience using the Mako intelligent robotic system in and outside the operating room.
5. New Applications of ROSA Surgical Robots
Equipment: ROSA Shoulder
Zimmer Biomet’s ROSA Shoulder robotic-assisted surgical system was approved by the FDA in February. The company’s ROSA Shoulder supports surgeons in total shoulder replacement using anatomical or reverse techniques. Through precise implant positioning, ROSA Shoulder helps improve surgical outcomes. According to Zimmer Biomet, ROSA Shoulder is one of the few systems that can accurately replicate the humeral head resection process. In addition, the system avoids the use of a needle in the center of the glenoid during surgery, simplifies the steps of inserting instruments into the incision, and thus improves the convenience and safety of the surgery.
Shenzhen Yujiaxin Tech Co., Ltd. specializes in the production of various types of laparoscopic surgical instrument forceps, surgical robot grasping forceps, electrocoagulation forceps, surgical blades, surgical grasping forceps, ultrasonic surgical blades, medical equipment parts and mechanical medical equipment parts, etc. The company also provides OEM customized processing services to meet the personalized needs of customers.
The powder metallurgy industry consists of three main segments:
Companies that produce powders, lubricants, industrial gases, and other raw materials used to make finished parts.
Companies that produce and provide tools, process equipment, and related services used to make finished parts.
Contract manufacturers and in-house manufacturers of finished parts.
Purpose of powder metallurgy products
The applications of powder metallurgy parts fall into two main categories. The first category is parts that are difficult to make by other methods, such as parts made of tungsten, molybdenum, or tungsten carbide. In addition, porous bearings, filters, and many types of hard and soft magnetic parts are made entirely using powder metallurgy. The second category is PM parts, which provide a cost-effective alternative to machined parts, castings, and forgings. Examples include automotive clutch plates, connecting rods, camshafts, and planetary gear carriers.
PM parts are used in a variety of markets, with the automotive industry being the main industry, consuming about 70% of the ferrous metal products produced by the industry each year. Other important markets include recreation, hand tools, and hobby products; household appliances; industrial motors and controllers; hardware; and commercial machines. And, as designers become more aware of the superior performance, unmatched tolerances, and cost savings that PM processes can provide, trends indicate that PM parts are continuing to expand into previously untapped markets—such as metal additive manufacturing.
Structural Components Market
Powder Metallurgy Industry Powder Metallurgy Industry The powder metallurgy industry consists of three segments, a complete chain from raw materials to finished parts, with each link supporting and being supported by the others.
1. Powder and Other Raw Materials Producers
These companies use a variety of technologies, including solid-state reduction, chemical, atomization, and electrolysis, to create powders, which are the cornerstone of powder metallurgy technology. The most common metal powders are steel, tin, nickel, copper, aluminum, and titanium, as well as refractory materials such as tungsten, molybdenum, and tantalum. Companies that make lubricants and other additives that are critical to the powder metallurgy process, as well as companies that make industrial gases used as sintering furnace atmospheres, belong to this part of the industry.
2. Process Equipment and Tool Manufacturers
This industry segment consists of companies engaged in the manufacture of equipment and technology for pressing and sintering powder metallurgy parts, including presses, injection molding machines, molds, and furnaces. It also includes suppliers of specialized equipment, systems, and support services for powder handling, secondary manufacturing and finishing operations, control automation, robotics, and laboratory testing.
3. Component and product producers
This segment includes companies that use existing molding technologies to manufacture finished parts. Most of these companies produce these parts while also acting as contractors for original equipment manufacturers (OEMs), who use them in their finished products, although a few companies are in-house suppliers to such OEMs.
In the field of metal powder metallurgy processing, Shenzhen Yujiaxin Technology Co., Ltd. not only has a professional technical team and advanced production equipment, but also focuses on technological innovation and research and development. The company is dedicated to Metal Injection Molding (MIM) and powder metallurgy processes, through which metal products with complex shapes, precise dimensions and excellent performance can be produced. At the same time, Yujiaxin Technology also focuses on the alloying of metal powders, surface treatment technology and the research and development of new powder materials, and continuously expands the application areas of metal powder metallurgy processing. These efforts have enabled the company to achieve significant success in high-tech industries such as automotive, aerospace, electronics, and medical devices.
Injection molding is a major manufacturing process that involves injecting molten material into a mold cavity under high pressure to quickly produce different parts. Although injection molding is mainly associated with plastics, it can also be applied to metal products through the metal injection molding (MIM) process.
Injection molding is a process that produces parts by injecting molten material into a mold. The process is widely used to mass produce plastic parts, but it can also be used to produce certain metal parts.
Basic process:
Injection: Molten material is injected into the mold cavity under high pressure.
Cooling: The material cools and solidifies inside the mold to form its shape.
Ejection: After cooling, the part is ejected from the mold.
Metal Injection Molding (MIM) Process
Metal injection molding (MIM) is a manufacturing process that combines the versatility of plastic injection molding with the strength and integrity of metal parts. It involves mixing fine metal powder with a binder to create a feedstock, which is then injected into the mold cavity. After molding, the binder is removed and the part is sintered to achieve its final properties.
Traditional Metalworking vs. MIM:
1. Complexity: MIM can produce more complex geometries than traditional methods such as machining or casting.
2. Material Use: MIM generally produces less waste than subtractive processes such as machining.
3. Production Volume: MIM is more cost-effective for medium to large volume production.
4. Finishing: MIM parts generally require less post-processing than traditionally manufactured parts.
MIM is particularly useful for producing small, complex metal parts for industries such as automotive, medical devices, and consumer electronics. It bridges the gap between the shape complexity of plastic injection molding and the material properties of metals.
Common Products of Injection Molding
Injection molding can produce many plastic and metal products. Injection molding is able to produce complex shapes with high precision and speed, making it the preferred method for producing a variety of products.
Here are some common categories of plastic products that are often made using injection molding:
Household goods
Containers, toys, and kitchen appliances
Industrial parts
Gears, brackets, and housings
Automotive parts
Instrument panels, trim, and under-the-hood components
Metal injection molding (MIM) expands the possibilities of metal part production and can be used to create complex, precision parts across a wide range of industries. The process combines the design freedom of plastic injection molding with the strength of metal.
Here are some common categories of metal products that are often made using injection molding:
Automotive parts
Engine parts, transmission parts, steering system parts
Medical devices
Surgical instruments, implants, diagnostic equipment parts
Industries that benefit from MIM include:
Aerospace
Automotive
Consumer electronics
Healthcare and medical devices
Firearms
Industrial machinery
Jewelry
Sporting goods
MIM’s ability to produce complex metal parts with high precision and consistency makes it invaluable in these fields. The process enables manufacturers to create parts that are difficult or impossible to produce using traditional metalworking methods, often at a lower cost and with less material waste.
Injection molding is at the forefront of modern manufacturing, demonstrating extraordinary versatility in both plastic and metal applications. The process has revolutionized production capabilities, making it possible to produce complex, precise and consistent parts at scale.
Shenzhen Yujiaxin Technology Co., Ltd., as a professional manufacturer in the field of Metal Injection Molding (MIM), is committed to providing customers with high-quality metal component solutions. The company utilizes advanced MIM technology, encompassing precise powder preparation, mixing, injection molding, as well as subsequent debinding and sintering processes, to produce metal products with complex shapes, precise dimensions, and excellent performance. During the MIM process, Yujiaxin Technology pays attention to every detail, from material selection to process control, ensuring the stability and reliability of product quality. Furthermore, the company boasts an experienced technical team capable of offering customized MIM processing solutions based on customers’ diverse needs. These solutions not only meet customers’ high requirements for metal components but also promote the application and development of MIM technology in more fields.
What are Iron-Nickel and Nickel-Steel Sintered Metals?
Iron-Nickel
Iron-Nickel is an alloy containing 1-4% nickel without carbon that has a unique set of properties. We use the inherent properties of Iron-Nickel alloys to produce parts with strength, increased fatigue strength and durability. Carbon is not present in this alloy, so during the sintering process, a fine, acicular martensite or bainite microstructure forms at the edges of the nickel particles.
Key Features:
Microstructure: Acicular martensite or bainite
Properties: Excellent strength and wear resistance
Nickel Content: 1-4%
Nickel-Steel Powdered Metal
Nickel-Steel powdered metal parts share similarities to Iron-Nickel materials, but stand out due to the addition of carbon. This combination enhances overall performance, creating a part with a balance of strength, wear and impact resistance. The addition of carbon creates a unique microstructure during the sintering process, ensuring optimal performance in a variety of applications.
Key Features:
Nickel Composition: varies with the addition of carbon
Microstructure: tailored for strength and wear resistance
Properties: high strength, wear resistance, high fatigue strength
Our iron-nickel and nickel-steel powder metal parts are widely used in the following industries:
Automotive: Precision components for engines, transmissions and structural parts with excellent strength and wear resistance.
Medical Devices: Custom parts designed for durability and wear resistance in medical devices.
Energy: Components in the energy sector, ensuring reliability and service life in demanding applications.
Industrial Machinery: Wear-resistant parts for heavy machinery, guaranteed to extend service life.
Shenzhen Yujiaxin Technology Co., Ltd. has been focusing on the field of Fe-Ni alloy metal powder metallurgy processing since its establishment, striving to become a leader in the industry. The company boasts a high-quality technical R&D team that, with advanced production processes and equipment, continues to innovate and develop a series of high-performance Fe-Ni alloy powder metallurgy products. These products not only exhibit excellent magnetic properties, corrosion resistance, and mechanical strength but are also widely used in various sectors such as automotive, electronics, aerospace, and more. During the Fe-Ni alloy metal powder metallurgy processing, the company emphasizes quality control in every step, from raw material selection, powder preparation, shaping, to sintering, all adhering to strict standards to ensure the stability and reliability of product performance. Furthermore, Yujiaxin Technology actively introduces internationally advanced testing technologies to conduct comprehensive performance tests on its products, catering to the diverse needs of customers.
The Revolutionary Application of Metal Injection Molding (MIM) Technology in the Medical Industry
The medical industry, as the forefront of technological advancements, is always committed to improving patient care and enhancing medical standards through innovative technologies. In recent years, Metal Injection Molding (MIM) technology has emerged as a prominent force in the manufacturing of medical equipment, surgical instruments, and tools, thanks to its unique advantages.
MIM technology is an advanced manufacturing process that combines the benefits of powder metallurgy and plastic injection molding. It enables the mass production of complex, high-strength metal components with excellent mechanical properties, such as high strength, hardness, good wear resistance, and corrosion resistance. These components achieve precise tolerance control, ensuring product stability and reliability. Furthermore, MIM technology offers a wide range of material choices, including stainless steel, titanium alloys, and cobalt-chromium alloys, meeting the diverse material needs of the medical industry.
The application of MIM technology is particularly significant in the medical field. Take surgical instruments as an example. Traditional machining methods often struggle with processing complex shapes and fine structures, while MIM technology can easily handle these challenges. Surgical instruments like forceps, scissors, and tweezers manufactured through MIM technology not only exhibit higher accuracy and consistency but also significantly shorten production cycles and improve production efficiency. For medical institutions, this means faster access to the required surgical instruments, thereby better serving patients.
In addition to surgical instruments, MIM technology also plays a crucial role in the manufacturing of medical equipment. For instance, it can be used to produce internal structural components, transmission parts, and connecting parts for medical equipment. These components need to withstand significant forces and pressures, requiring high material strength and wear resistance. Through precise powder blending and sintering processes, MIM technology can produce metal components that meet these requirements, ensuring the stability and reliability of medical equipment.
It’s worth mentioning that MIM technology also offers cost-effectiveness advantages. Compared with traditional machining methods, MIM technology can greatly reduce material waste and processing costs. Moreover, since MIM technology enables mass production, it can further lower the cost per unit product. For medical device manufacturers, this means creating a more streamlined supply chain without sacrificing quality, thereby enhancing market competitiveness.
Shenzhen Yujiaxin Technology Co., Ltd., as a leader in MIM technology, fully understands the importance of this technology in the medical industry. The company not only possesses advanced MIM production equipment and a skilled technical team but also strives to apply MIM technology to more medical products. Through continuous research and innovation, Yujiaxin Technology has successfully applied MIM technology to the manufacturing of products such as surgical forceps, endoscopic forceps, and ultrasonic scalpel blades, achieving remarkable results.
Looking ahead, with the continuous development of the medical industry and the increasing demand for high-quality, efficient manufacturing technologies, MIM technology will play an even more crucial role in the medical field. Shenzhen Yujiaxin Technology Co., Ltd. will continue to adhere to the principles of innovation, quality, and service, providing the medical industry with more high-quality, efficient MIM solutions to drive its sustained development.
Plating is a surface covering where metal is deposited onto a conductive surface. Plating can be used to inhibit corrosion, improve solderability, harden, improve wear resistance, reduce friction, improve paint adhesion, change conductivity, or for radiation shielding.
Aerospace plating is essential to the survival and growth of the industry. Reliability, precision, and using the right materials are essential.
Painting:
As with any type of painting, applying a wet coat of paint to the metal surface is a necessity for metal painting. Typically, manufacturers use pumps, sprayers, or pressurized containers to ensure that the paint is evenly applied.
Polishing and Sanding:
Polishing involves scraping away surface material in order to achieve a better finish and prepare it for polishing. Polishing produces a high gloss, sometimes called a mirror effect, and smooths the surface.
Sandblasting:
With sandblasting, you can easily combine cleaning and finishing into one procedure. To achieve the necessary cleanliness and surface profile, abrasive particles are sprayed at high pressure onto the metal surface during sandblasting. Abrasives such as sand, glass, plastic, and aluminum oxide are used in this technique.
Black Oxide：
Black oxide is a conversion coating applied to iron, zinc, steel, stainless steel and copper. It gives a black, smooth finish and improves corrosion and wear resistance. Black oxide is commonly used as a surface treatment for a variety of industrial and commercial applications, including automotive and aerospace components, machinery and tools.
· Fasteners, hardware and tools.
· Automotive and aerospace components, black oxide is used as a surface treatment for a variety of parts, including engine components, defense parts.
Manganese Phosphating：
Manganese phosphating is well known as a wear protection measure and is widely used in the automotive/aerospace/defense industries. It is widely used to improve the sliding properties of engines, gears and power transmission systems. It has the highest hardness and superior corrosion and wear resistance to general phosphate coatings. Among other industries, manganese phosphating coatings are used in almost all metalworking industries to improve corrosion resistance.
Galvanizing:
Galvanizing is the process of covering a base metal (such as steel and iron, etc.) with a layer or coating of zinc to protect the base metal from corrosion.
Anodizing:
Anodizing is a simple electrochemical process that coats aluminum surfaces with a protective layer of aluminum oxide. The thickness of the anodic coating applied determines the life of the surface.
Aluminium oxide is tough, resilient and weather resistant and protects the base metal. The coating may have a tinted hue or appear bronze due to the diffraction effect created by the coating.
Shenzhen Yujiaxin Technology Co., Ltd., since its inception, has been dedicated to the research and development of Metal Injection Molding (MIM) technology. The company boasts a high-quality technical team that leverages advanced production equipment and exquisite craftsmanship to provide clients with one-stop MIM solutions. From product design, mold development, material selection to mass production, Yujiaxin Technology strictly controls every step to ensure high precision and quality of its products. The company’s main products include, but are not limited to, injection-molded parts made of stainless steel, titanium alloys, copper alloys, and other metals, which are widely used in various fields such as automotive, medical, electronics, and communications. Through continuous innovation and optimization, Yujiaxin Technology has become a leader in the metal injection molding processing industry, earning widespread praise from domestic and international clients.
In the vibrant realm of modern engineering, the trajectory of metal powder embodies a captivating saga of metamorphosis, threading through a series of intricate stages including scrap collection, melting, atomization, quality evaluation, manufacturing, and ultimately, a sustainable reincarnation. This fascinating journey not only fuels industries like automotive, aerospace, and medical but also epitomizes the fusion of innovation and accountability within today’s industrial world.
Melting
Within the crucible of advanced metallurgical processes, a diverse array of scrap metals is collected, each harboring latent potential awaiting realization. Meticulous melting procedures eradicate impurities from these metals, paving the way for a profound metamorphosis.
Atomization
Following the melting phase, the molten metal embarks on a journey of atomization. This intricate process entails the controlled expulsion of molten metal through specialized nozzles, where it encounters precisely directed streams of gas or water. The outcome manifests as the creation of metal particles spanning from 250µm to less than 25µm in size. Subsequently, water-atomized powder undergoes drying and annealing in a hydrogen-rich environment to eliminate surface oxides formed during atomization. This finely powdered metal emerges as the cornerstone of numerous industrial applications.
Rigorous Testing Standards
At this pivotal juncture, rigorous quality assessments are conducted on the metal powder. Thorough testing for critical attributes, including chemical composition, particle size distribution, apparent density, flow characteristics, and compressibility, is executed to ensure adherence to industry standards. Such meticulous quality control not only ensures the versatility of the metal powder but also guarantees compatibility with diverse manufacturing processes on the horizon.
Applications
Endowed with certification and refinement, the metal powder now transitions into the manufacturing realm. Its innate versatility facilitates seamless integration into various production methodologies such as compaction, 3D printing, direct energy deposition, or injection molding. This finely powdered metal serves as the fundamental building block for essential components in automobiles, aircraft, medical devices, and numerous other applications, highlighting its versatility and importance across diverse industries. It has also made recent strides in the fields of magnetics and electrification.
Recycling & Sustainability
At the end of this lifecycle, the metal powder exemplifies the principles of sustainability. As the part nears the conclusion of its operational life, conscientious practices come into play. The metal powder is reclaimed and reintroduced into the crucible as metal scrap, thereby completing the cycle. This approach epitomizes the essence of the circular economy, mitigating waste generation and fostering environmental stewardship.
The lifecycle of metal powder is a technological marvel on its own; it constitutes a narrative of conscientious industrial practices, seamlessly melding innovation with a steadfast commitment to sustainability. As we navigate the intricacies of metallurgical processes, we chart a course towards a future characterized by efficiency, environmental consciousness, and boundless potential. The journey of metal powder serves as a guiding beacon, illuminating the path towards a harmonious coalescence of industry and ecology.
Shenzhen Yujiaxin Technology Co., Ltd., as a prominent player in the metal powder processing industry, has been deeply rooted in the field of metal powder metallurgy since its inception, striving to become a leader in innovation and quality. The company specializes in the entire process technology of metal powder preparation, modification, forming, and sintering, encompassing the research and production of various metal powder metallurgy materials such as iron-based, copper-based, aluminum-based, and nickel-based powders. By adopting advanced powder metallurgy techniques, including Metal Injection Molding (MIM), Powder Metallurgy Pressing (PM), and Laser Cladding, Yujiaxin Technology not only enhances the precision and performance of metal components but also significantly shortens production cycles and reduces manufacturing costs. With a focus on integrating technological innovation with customer needs, the company provides high-performance, customized metal powder metallurgy solutions for numerous industries, including automotive, aerospace, electronics and information, medical devices, and more. This truly realizes a one-stop service from raw materials to finished products, highlighting its core competitiveness and professional status within the metal powder metallurgy supply chain.
Explore the challenges and solutions of appearance quality in MIM production
In the field of metal injection molding (MIM) and powder metallurgy production, the appearance quality of parts is not only the focus of customers, but also a key yardstick for measuring the stability of production processes and product reliability. However, due to the complexity of the process, appearance defects occur from time to time, which has become a major challenge in the production process. Next, through this blog, I will discuss with you several common appearance defects, the reasons behind them, and practical solutions.
1. Rough surface: a stumbling block in the process journey
If the surface of the part appears rough and uneven, it will not only affect the visual beauty, but also may weaken its overall performance. This is usually due to uneven powder particle size, poor mold quality or improper injection parameters.
Improvement method:
-Choose finer and more uniform powder raw materials to ensure a solid material foundation.
-Carefully adjust the injection pressure and speed to allow the material to flow freely in the mold to form a smooth surface.
-Regular cleaning and polishing of the mold is essential, because the “appearance” of the mold directly determines the “face” of the part.
2. Uneven shrinkage: an invisible threat to precision
If the sintered parts are uneven in size or deformed, it may be caused by uneven material mixing, too high sintering temperature or unreasonable mold design.
Improvement method:
-Ensure that the powder and binder are fully mixed to reduce internal stress
-Accurately control the heating rate and holding time during sintering, and treat each product like a treasure.
-Consider the uniformity of wall thickness when designing the mold to ensure that the parts remain stable during the sintering process.
3. Cracking: a hard flaw that cannot be ignored
Cracks that appear in parts during degreasing or sintering are often caused by the accumulation of internal stress or the influence of residual gas.
Improvement method:
-Carry out degreasing treatment in stages, starting from low temperature and gradually releasing internal stress.
-Ensure that the degreasing process is thorough, especially for parts with complex shapes, to ensure that the gas exhaust channel is unobstructed.
-Improve the injection process to avoid uneven filling and ensure the integrity of the internal structure of the parts.
4. Deformation: Accidents during sintering
If parts bend or deform after sintering, it may be caused by excessive temperature or insufficient support.
Improvement methods:
-Adjust the sintering curve to find the most suitable temperature range.
-Use sintering fixtures to provide support for complex parts to ensure that they maintain a stable shape in a high temperature environment.
-Optimize the mold demolding design to reduce shape deviation caused by stress concentration.
5. Black spots or spots: surface defects
These defects may be caused by material oxidation, mold contamination or impurities. Although small, they affect the overall appearance.
Improvement methods:
-Use high-purity powder raw materials to avoid oxidation and impurity contamination.
-Clean the mold regularly and strictly control the amount of release agent used.
-Improve the production environment, reduce the interference of dust and foreign matter, and keep the production area clean.
6. Color difference: the individuality of the process
The inconsistent color of the sintered parts is usually due to uneven material composition or improper control of the sintering atmosphere.
Improvement methods:
-Ensure that the raw materials are mixed evenly to make the parts consistent inside and outside.
-Adjust the sintering atmosphere, such as using a reducing atmosphere, to avoid excessive oxidation reaction.
-Regularly update the injection material to avoid performance fluctuations caused by material aging.
7. Flash: unnecessary troubles
Flash is the direct result of poor mold closure or excessive injection pressure, which increases the difficulty of subsequent processing.
Improvement method:
-Regularly inspect the mold to ensure tight and seamless closure.
-Adjust the injection pressure to the optimal value to ensure complete filling without overflow.
Shenzhen Yujiaxin Technology Co., Ltd., driven by innovation, uses cutting-edge titanium alloy metal powder injection molding technology to carefully create various medical devices and medical implant parts. We are committed to providing high-precision and high-reliability products to ensure the health and safety of every patient. Whether it is a complex pacemaker or a tiny dental implant, we can manufacture it accurately and perfectly match it. Choose Yujiaxin, choose trust and peace of mind.
Application of powder metallurgy in power tool parts
Against the background of the rapid development of the power tool industry, there is an increasing demand for high-performance, durable and affordable parts. Powder metallurgy (PM) technology is gradually emerging as an innovator in this field. The unique properties of metal powders allow manufacturers to create parts that meet the demanding standards of modern power tools. This article will delve into the unique advantages of powder metallurgy in power tool components and highlight its key applications.
Powder metallurgy, simply put, is a process of manufacturing solid metal parts by pressing and sintering metal powder. This technology allows manufacturers to precisely control the density, strength and dimensional accuracy of the final product, and is particularly suitable for producing complex shapes and designs that are difficult to achieve with traditional processing methods.
In the field of power tools, powder metallurgy shows significant advantages.
First, from a cost-effectiveness perspective, powder metallurgy significantly reduces material waste through near-net shape production and reduces the need for extensive machining, thereby effectively controlling production costs.
Second, parts manufactured through powder metallurgy often have superior mechanical properties, such as higher strength, hardness, and wear resistance, which are critical for frequently used power tools.
Additionally, powder metallurgy offers design flexibility, allowing manufacturers to create custom parts with internal cooling channels or complex geometries to meet specific tooling requirements.
Finally, PM components can also be optimized for power tool performance, such as by customizing porosity to enhance lubrication retention, thereby improving performance and service life in high-speed applications.
In power tools, the application of powder metallurgy is widespread and critical. Gear components are an important part of this. Powder metallurgy technology can produce high-precision and high-strength gears to ensure effective power transmission and long life of power tools such as electric drills and saws. In addition, components such as the stator and rotor in electric motors also benefit from powder metallurgy technology, which ensures that the motor performs optimally in the application by producing complex-shaped and high-density components to provide the required power and efficiency.
Cutting tools produced by powder metallurgy have also attracted much attention. Their high hardness and wear resistance allow the tools to maintain longer service life and sharpness under challenging conditions. At the same time, powder metallurgy is also used to make housings and protective cases for power tools. These parts are designed to be both lightweight and strong, providing protection while reducing the overall weight of the tool.
As the power tool market continues to grow and develop, powder metallurgy is becoming increasingly important as a key technology for producing high-quality components. With its cost-effectiveness, design flexibility and enhanced mechanical properties, powder metallurgy is changing manufacturers’ strategies in the production of power tool components.
Shenzhen Yujiaxin Technology Co., Ltd., as a leader in the field of powder metallurgy, specializes in the preparation, forming, and sintering of metal powders, committed to providing high-quality powder metallurgy products. We employ advanced atomization techniques to ensure uniform particle size and high purity of the metal powders, laying a solid foundation for subsequent pressing and sintering processes. Through precise mold design and optimization, we achieve one-time forming of complex-shaped parts, significantly enhancing production efficiency and product accuracy. During the sintering process, we utilize high-temperature vacuum furnaces to precisely control the sintering curve, ensuring material densification and optimal performance. Our powder metallurgy products, distinguished by their excellent mechanical properties, good dimensional stability, and cost-effectiveness, are widely used in various industries including automotive, aerospace, electronics, and more.
Skerlin Fang
Powder Metal Parts and Powder Metallurgy Process Overview
Powder metals are alloys that are processed into fine, granular powders through one of a variety of processes. These metals are primarily made of stainless steel, brass, copper, iron, or bronze and can be blended with other alloys to achieve the material properties and characteristics required for a specific application. Powder metal parts offer greater flexibility in material use and mechanical properties, can be highly customized and easily replicated, while producing high-strength, cost-effective components.
Making High-Strength Components
Powder metallurgy (PM) refers to a manufacturing process that forms powdered metal or metal mixtures into desired specifications through a unique combination of heat and compression, resulting in parts and components that are stronger than traditional forging processes.
The process is shorter than other manufacturing techniques, and the main steps include the following:
1. The metal is made into powder through chemical treatments such as solid-state reduction, atomization, electrolysis, or oxide reduction and thermal decomposition.
2. The powder is mixed with other metals, alloying agents, and lubricants to reduce friction, increase flow, and produce a homogenous mixture, which is then fed into a rigid tooling set for processing.
3. The metal mixture is compressed into the appropriate geometry using dies, punches, hydraulic presses, or other consolidation measures.
4. The compacted fragments are sintered in a controlled atmosphere, using extremely high temperatures to metallurgically bond the particles.
5. Secondary operations are performed on the parts, depending on the requirements of the end application.
The PM process is considered environmentally friendly because it produces harmless nitrogen and hydrogen byproducts, while also limiting production waste by utilizing more than 97% of the material entering the process.
Heat Treatment and Finishing Options
After sintering, parts may undergo additional heat treatment or finishing to increase material strength and hardness, improve corrosion resistance, improve part tolerances, enhance surface finish, etc.
Secondary operations include the following:
· Heat treatment: quenching, tempering, steam treatment, furnace welding, etc.
· Machining: drilling and tapping, turning, milling or grinding
· Impregnation: oil or resin
· Finishing: deburring, tumbling, polishing, coating or plating, welding, etc.
Shenzhen Yujiaxin Technology Co., Ltd. has been specializing in the field of metal powder metallurgy processing since its establishment, dedicating itself to the research and development of the entire chain technology including metal powder preparation, forming, sintering, and post-treatment. Leveraging advanced Metal Injection Molding (MIM), Powder Metallurgy Pressing (PM), and Powder Metallurgy Copper Infiltration techniques, the company provides high-precision, high-performance metal component solutions for various industries such as automotive, electronics, communications, and medical devices. Through continuous optimization of production processes, Yujiaxin Technology has significantly enhanced product density, hardness, and wear resistance, earning widespread recognition in the market.
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Skerlin Fang
5 New Innovative Medical Devices to Watch Out For!
From pulsed field ablation to diabetes and surgical robotics, there are many important medical devices being launched.
1. Pulsed Field Ablation
Device: Farapulse
The system was acquired by Boston Scientific in 2021 for nearly $300 million. The entire system includes the Farawave ablation catheter, Farastar ablation generator, and Faradrive steerable sheath, which together provide pulsed field energy. Farapulse uses non-thermal treatment technology to selectively ablate cardiac tissue through electric fields, and its catheter design is unique. It is an online catheter with a variable shape that can adapt to the pulmonary venous anatomy of different patients to achieve personalized treatment.
2. Tricuspid Valve Replacement
Device: Evoque Tricuspid
Evoque is a transcatheter therapy designed by Edwards Lifesciences specifically for the treatment of tricuspid regurgitation. The therapy received FDA approval in February, becoming the first FDA-approved transcatheter device for tricuspid regurgitation. Evoque features a nitinol self-expanding frame, annular skirt, and tissue leaflets made from bovine pericardial tissue.
3. Continuous Glucose Monitoring
Device: Non-insulin Designed CGM
Stelo CGM is a 15-day continuous glucose monitoring system designed by Dexcom, and the software experience is specifically customized for non-insulin dependent diabetics.
Shortly after Dexcom submitted its application to the FDA, company CEO Kevin Sayer told Drug Delivery Business News that Stelo CGM was designed with non-insulin users in mind and would not “bother” users with frequent alerts and reminders, but instead provide the personalized insights users need. As a result, Sayer noted that the company’s production line is ready for production. In addition, it is worth noting that Stelo CGM was not initially promoted as a cash payment option, but was acquired through an over-the-counter transaction in March.
4. Surgical Robotic Applications
Equipment: Mako Spine/Shoulder
Early last year, Stryker said that its Mako surgical robotic platform will achieve significant application expansion in 2024. Mako Spine is an application combined with the company’s new bone cutting product. And Mako Shoulder will use robotic applications to increase incremental precision.
In addition, Stryker will continue to expand the scope of Mako’s applications. Earlier this year, they launched a new medium to enhance the surgeon’s experience using the Mako intelligent robotic system in and outside the operating room.
5. New Applications of ROSA Surgical Robots
Equipment: ROSA Shoulder
Zimmer Biomet’s ROSA Shoulder robotic-assisted surgical system was approved by the FDA in February. The company’s ROSA Shoulder supports surgeons in total shoulder replacement using anatomical or reverse techniques. Through precise implant positioning, ROSA Shoulder helps improve surgical outcomes. According to Zimmer Biomet, ROSA Shoulder is one of the few systems that can accurately replicate the humeral head resection process. In addition, the system avoids the use of a needle in the center of the glenoid during surgery, simplifies the steps of inserting instruments into the incision, and thus improves the convenience and safety of the surgery.
Shenzhen Yujiaxin Tech Co., Ltd. specializes in the production of various types of laparoscopic surgical instrument forceps, surgical robot grasping forceps, electrocoagulation forceps, surgical blades, surgical grasping forceps, ultrasonic surgical blades, medical equipment parts and mechanical medical equipment parts, etc. The company also provides OEM customized processing services to meet the personalized needs of customers.
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Skerlin Fang
Current state of the powder metallurgy industry
The powder metallurgy industry consists of three main segments:
Companies that produce powders, lubricants, industrial gases, and other raw materials used to make finished parts.
Companies that produce and provide tools, process equipment, and related services used to make finished parts.
Contract manufacturers and in-house manufacturers of finished parts.
Purpose of powder metallurgy products
The applications of powder metallurgy parts fall into two main categories. The first category is parts that are difficult to make by other methods, such as parts made of tungsten, molybdenum, or tungsten carbide. In addition, porous bearings, filters, and many types of hard and soft magnetic parts are made entirely using powder metallurgy. The second category is PM parts, which provide a cost-effective alternative to machined parts, castings, and forgings. Examples include automotive clutch plates, connecting rods, camshafts, and planetary gear carriers.
PM parts are used in a variety of markets, with the automotive industry being the main industry, consuming about 70% of the ferrous metal products produced by the industry each year. Other important markets include recreation, hand tools, and hobby products; household appliances; industrial motors and controllers; hardware; and commercial machines. And, as designers become more aware of the superior performance, unmatched tolerances, and cost savings that PM processes can provide, trends indicate that PM parts are continuing to expand into previously untapped markets—such as metal additive manufacturing.
Structural Components Market
Powder Metallurgy Industry Powder Metallurgy Industry The powder metallurgy industry consists of three segments, a complete chain from raw materials to finished parts, with each link supporting and being supported by the others.
1. Powder and Other Raw Materials Producers
These companies use a variety of technologies, including solid-state reduction, chemical, atomization, and electrolysis, to create powders, which are the cornerstone of powder metallurgy technology. The most common metal powders are steel, tin, nickel, copper, aluminum, and titanium, as well as refractory materials such as tungsten, molybdenum, and tantalum. Companies that make lubricants and other additives that are critical to the powder metallurgy process, as well as companies that make industrial gases used as sintering furnace atmospheres, belong to this part of the industry.
2. Process Equipment and Tool Manufacturers
This industry segment consists of companies engaged in the manufacture of equipment and technology for pressing and sintering powder metallurgy parts, including presses, injection molding machines, molds, and furnaces. It also includes suppliers of specialized equipment, systems, and support services for powder handling, secondary manufacturing and finishing operations, control automation, robotics, and laboratory testing.
3. Component and product producers
This segment includes companies that use existing molding technologies to manufacture finished parts. Most of these companies produce these parts while also acting as contractors for original equipment manufacturers (OEMs), who use them in their finished products, although a few companies are in-house suppliers to such OEMs.
In the field of metal powder metallurgy processing, Shenzhen Yujiaxin Technology Co., Ltd. not only has a professional technical team and advanced production equipment, but also focuses on technological innovation and research and development. The company is dedicated to Metal Injection Molding (MIM) and powder metallurgy processes, through which metal products with complex shapes, precise dimensions and excellent performance can be produced. At the same time, Yujiaxin Technology also focuses on the alloying of metal powders, surface treatment technology and the research and development of new powder materials, and continuously expands the application areas of metal powder metallurgy processing. These efforts have enabled the company to achieve significant success in high-tech industries such as automotive, aerospace, electronics, and medical devices.
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Skerlin Fang
Metal Injection Products
Injection molding is a major manufacturing process that involves injecting molten material into a mold cavity under high pressure to quickly produce different parts. Although injection molding is mainly associated with plastics, it can also be applied to metal products through the metal injection molding (MIM) process.
Injection molding is a process that produces parts by injecting molten material into a mold. The process is widely used to mass produce plastic parts, but it can also be used to produce certain metal parts.
Basic process:
Injection: Molten material is injected into the mold cavity under high pressure.
Cooling: The material cools and solidifies inside the mold to form its shape.
Ejection: After cooling, the part is ejected from the mold.
Metal Injection Molding (MIM) Process
Metal injection molding (MIM) is a manufacturing process that combines the versatility of plastic injection molding with the strength and integrity of metal parts. It involves mixing fine metal powder with a binder to create a feedstock, which is then injected into the mold cavity. After molding, the binder is removed and the part is sintered to achieve its final properties.
Traditional Metalworking vs. MIM:
1. Complexity: MIM can produce more complex geometries than traditional methods such as machining or casting.
2. Material Use: MIM generally produces less waste than subtractive processes such as machining.
3. Production Volume: MIM is more cost-effective for medium to large volume production.
4. Finishing: MIM parts generally require less post-processing than traditionally manufactured parts.
MIM is particularly useful for producing small, complex metal parts for industries such as automotive, medical devices, and consumer electronics. It bridges the gap between the shape complexity of plastic injection molding and the material properties of metals.
Common Products of Injection Molding
Injection molding can produce many plastic and metal products. Injection molding is able to produce complex shapes with high precision and speed, making it the preferred method for producing a variety of products.
Here are some common categories of plastic products that are often made using injection molding:
Household goods
Containers, toys, and kitchen appliances
Industrial parts
Gears, brackets, and housings
Automotive parts
Instrument panels, trim, and under-the-hood components
Metal injection molding (MIM) expands the possibilities of metal part production and can be used to create complex, precision parts across a wide range of industries. The process combines the design freedom of plastic injection molding with the strength of metal.
Here are some common categories of metal products that are often made using injection molding:
Automotive parts
Engine parts, transmission parts, steering system parts
Electronics
Connectors, housings, internal components
Medical devices
Surgical instruments, implants, diagnostic equipment parts
Industries that benefit from MIM include:
Aerospace
Automotive
Consumer electronics
Healthcare and medical devices
Firearms
Industrial machinery
Jewelry
Sporting goods
MIM’s ability to produce complex metal parts with high precision and consistency makes it invaluable in these fields. The process enables manufacturers to create parts that are difficult or impossible to produce using traditional metalworking methods, often at a lower cost and with less material waste.
Injection molding is at the forefront of modern manufacturing, demonstrating extraordinary versatility in both plastic and metal applications. The process has revolutionized production capabilities, making it possible to produce complex, precise and consistent parts at scale.
Shenzhen Yujiaxin Technology Co., Ltd., as a professional manufacturer in the field of Metal Injection Molding (MIM), is committed to providing customers with high-quality metal component solutions. The company utilizes advanced MIM technology, encompassing precise powder preparation, mixing, injection molding, as well as subsequent debinding and sintering processes, to produce metal products with complex shapes, precise dimensions, and excellent performance. During the MIM process, Yujiaxin Technology pays attention to every detail, from material selection to process control, ensuring the stability and reliability of product quality. Furthermore, the company boasts an experienced technical team capable of offering customized MIM processing solutions based on customers’ diverse needs. These solutions not only meet customers’ high requirements for metal components but also promote the application and development of MIM technology in more fields.
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Skerlin Fang
What are Iron-Nickel and Nickel-Steel Sintered Metals?
Iron-Nickel
Iron-Nickel is an alloy containing 1-4% nickel without carbon that has a unique set of properties. We use the inherent properties of Iron-Nickel alloys to produce parts with strength, increased fatigue strength and durability. Carbon is not present in this alloy, so during the sintering process, a fine, acicular martensite or bainite microstructure forms at the edges of the nickel particles.
Key Features:
Microstructure: Acicular martensite or bainite
Properties: Excellent strength and wear resistance
Nickel Content: 1-4%
Nickel-Steel Powdered Metal
Nickel-Steel powdered metal parts share similarities to Iron-Nickel materials, but stand out due to the addition of carbon. This combination enhances overall performance, creating a part with a balance of strength, wear and impact resistance. The addition of carbon creates a unique microstructure during the sintering process, ensuring optimal performance in a variety of applications.
Key Features:
Nickel Composition: varies with the addition of carbon
Microstructure: tailored for strength and wear resistance
Properties: high strength, wear resistance, high fatigue strength
Our iron-nickel and nickel-steel powder metal parts are widely used in the following industries:
Automotive: Precision components for engines, transmissions and structural parts with excellent strength and wear resistance.
Medical Devices: Custom parts designed for durability and wear resistance in medical devices.
Energy: Components in the energy sector, ensuring reliability and service life in demanding applications.
Industrial Machinery: Wear-resistant parts for heavy machinery, guaranteed to extend service life.
Shenzhen Yujiaxin Technology Co., Ltd. has been focusing on the field of Fe-Ni alloy metal powder metallurgy processing since its establishment, striving to become a leader in the industry. The company boasts a high-quality technical R&D team that, with advanced production processes and equipment, continues to innovate and develop a series of high-performance Fe-Ni alloy powder metallurgy products. These products not only exhibit excellent magnetic properties, corrosion resistance, and mechanical strength but are also widely used in various sectors such as automotive, electronics, aerospace, and more. During the Fe-Ni alloy metal powder metallurgy processing, the company emphasizes quality control in every step, from raw material selection, powder preparation, shaping, to sintering, all adhering to strict standards to ensure the stability and reliability of product performance. Furthermore, Yujiaxin Technology actively introduces internationally advanced testing technologies to conduct comprehensive performance tests on its products, catering to the diverse needs of customers.
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Skerlin Fang
The Revolutionary Application of Metal Injection Molding (MIM) Technology in the Medical Industry
The medical industry, as the forefront of technological advancements, is always committed to improving patient care and enhancing medical standards through innovative technologies. In recent years, Metal Injection Molding (MIM) technology has emerged as a prominent force in the manufacturing of medical equipment, surgical instruments, and tools, thanks to its unique advantages.
MIM technology is an advanced manufacturing process that combines the benefits of powder metallurgy and plastic injection molding. It enables the mass production of complex, high-strength metal components with excellent mechanical properties, such as high strength, hardness, good wear resistance, and corrosion resistance. These components achieve precise tolerance control, ensuring product stability and reliability. Furthermore, MIM technology offers a wide range of material choices, including stainless steel, titanium alloys, and cobalt-chromium alloys, meeting the diverse material needs of the medical industry.
The application of MIM technology is particularly significant in the medical field. Take surgical instruments as an example. Traditional machining methods often struggle with processing complex shapes and fine structures, while MIM technology can easily handle these challenges. Surgical instruments like forceps, scissors, and tweezers manufactured through MIM technology not only exhibit higher accuracy and consistency but also significantly shorten production cycles and improve production efficiency. For medical institutions, this means faster access to the required surgical instruments, thereby better serving patients.
In addition to surgical instruments, MIM technology also plays a crucial role in the manufacturing of medical equipment. For instance, it can be used to produce internal structural components, transmission parts, and connecting parts for medical equipment. These components need to withstand significant forces and pressures, requiring high material strength and wear resistance. Through precise powder blending and sintering processes, MIM technology can produce metal components that meet these requirements, ensuring the stability and reliability of medical equipment.
It’s worth mentioning that MIM technology also offers cost-effectiveness advantages. Compared with traditional machining methods, MIM technology can greatly reduce material waste and processing costs. Moreover, since MIM technology enables mass production, it can further lower the cost per unit product. For medical device manufacturers, this means creating a more streamlined supply chain without sacrificing quality, thereby enhancing market competitiveness.
Shenzhen Yujiaxin Technology Co., Ltd., as a leader in MIM technology, fully understands the importance of this technology in the medical industry. The company not only possesses advanced MIM production equipment and a skilled technical team but also strives to apply MIM technology to more medical products. Through continuous research and innovation, Yujiaxin Technology has successfully applied MIM technology to the manufacturing of products such as surgical forceps, endoscopic forceps, and ultrasonic scalpel blades, achieving remarkable results.
Looking ahead, with the continuous development of the medical industry and the increasing demand for high-quality, efficient manufacturing technologies, MIM technology will play an even more crucial role in the medical field. Shenzhen Yujiaxin Technology Co., Ltd. will continue to adhere to the principles of innovation, quality, and service, providing the medical industry with more high-quality, efficient MIM solutions to drive its sustained development.
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Skerlin Fang
Metal surface treatment encyclopedia
Plating:
Plating is a surface covering where metal is deposited onto a conductive surface. Plating can be used to inhibit corrosion, improve solderability, harden, improve wear resistance, reduce friction, improve paint adhesion, change conductivity, or for radiation shielding.
Aerospace plating is essential to the survival and growth of the industry. Reliability, precision, and using the right materials are essential.
Painting:
As with any type of painting, applying a wet coat of paint to the metal surface is a necessity for metal painting. Typically, manufacturers use pumps, sprayers, or pressurized containers to ensure that the paint is evenly applied.
Polishing and Sanding:
Polishing involves scraping away surface material in order to achieve a better finish and prepare it for polishing. Polishing produces a high gloss, sometimes called a mirror effect, and smooths the surface.
Sandblasting:
With sandblasting, you can easily combine cleaning and finishing into one procedure. To achieve the necessary cleanliness and surface profile, abrasive particles are sprayed at high pressure onto the metal surface during sandblasting. Abrasives such as sand, glass, plastic, and aluminum oxide are used in this technique.
Black Oxide：
Black oxide is a conversion coating applied to iron, zinc, steel, stainless steel and copper. It gives a black, smooth finish and improves corrosion and wear resistance. Black oxide is commonly used as a surface treatment for a variety of industrial and commercial applications, including automotive and aerospace components, machinery and tools.
· Fasteners, hardware and tools.
· Automotive and aerospace components, black oxide is used as a surface treatment for a variety of parts, including engine components, defense parts.
Manganese Phosphating：
Manganese phosphating is well known as a wear protection measure and is widely used in the automotive/aerospace/defense industries. It is widely used to improve the sliding properties of engines, gears and power transmission systems. It has the highest hardness and superior corrosion and wear resistance to general phosphate coatings. Among other industries, manganese phosphating coatings are used in almost all metalworking industries to improve corrosion resistance.
Galvanizing:
Galvanizing is the process of covering a base metal (such as steel and iron, etc.) with a layer or coating of zinc to protect the base metal from corrosion.
Anodizing:
Anodizing is a simple electrochemical process that coats aluminum surfaces with a protective layer of aluminum oxide. The thickness of the anodic coating applied determines the life of the surface.
Aluminium oxide is tough, resilient and weather resistant and protects the base metal. The coating may have a tinted hue or appear bronze due to the diffraction effect created by the coating.
Shenzhen Yujiaxin Technology Co., Ltd., since its inception, has been dedicated to the research and development of Metal Injection Molding (MIM) technology. The company boasts a high-quality technical team that leverages advanced production equipment and exquisite craftsmanship to provide clients with one-stop MIM solutions. From product design, mold development, material selection to mass production, Yujiaxin Technology strictly controls every step to ensure high precision and quality of its products. The company’s main products include, but are not limited to, injection-molded parts made of stainless steel, titanium alloys, copper alloys, and other metals, which are widely used in various fields such as automotive, medical, electronics, and communications. Through continuous innovation and optimization, Yujiaxin Technology has become a leader in the metal injection molding processing industry, earning widespread praise from domestic and international clients.
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Skerlin Fang
Lifecycle of Metal Powder
In the vibrant realm of modern engineering, the trajectory of metal powder embodies a captivating saga of metamorphosis, threading through a series of intricate stages including scrap collection, melting, atomization, quality evaluation, manufacturing, and ultimately, a sustainable reincarnation. This fascinating journey not only fuels industries like automotive, aerospace, and medical but also epitomizes the fusion of innovation and accountability within today’s industrial world.
Melting
Within the crucible of advanced metallurgical processes, a diverse array of scrap metals is collected, each harboring latent potential awaiting realization. Meticulous melting procedures eradicate impurities from these metals, paving the way for a profound metamorphosis.
Atomization
Following the melting phase, the molten metal embarks on a journey of atomization. This intricate process entails the controlled expulsion of molten metal through specialized nozzles, where it encounters precisely directed streams of gas or water. The outcome manifests as the creation of metal particles spanning from 250µm to less than 25µm in size. Subsequently, water-atomized powder undergoes drying and annealing in a hydrogen-rich environment to eliminate surface oxides formed during atomization. This finely powdered metal emerges as the cornerstone of numerous industrial applications.
Rigorous Testing Standards
At this pivotal juncture, rigorous quality assessments are conducted on the metal powder. Thorough testing for critical attributes, including chemical composition, particle size distribution, apparent density, flow characteristics, and compressibility, is executed to ensure adherence to industry standards. Such meticulous quality control not only ensures the versatility of the metal powder but also guarantees compatibility with diverse manufacturing processes on the horizon.
Applications
Endowed with certification and refinement, the metal powder now transitions into the manufacturing realm. Its innate versatility facilitates seamless integration into various production methodologies such as compaction, 3D printing, direct energy deposition, or injection molding. This finely powdered metal serves as the fundamental building block for essential components in automobiles, aircraft, medical devices, and numerous other applications, highlighting its versatility and importance across diverse industries. It has also made recent strides in the fields of magnetics and electrification.
Recycling & Sustainability
At the end of this lifecycle, the metal powder exemplifies the principles of sustainability. As the part nears the conclusion of its operational life, conscientious practices come into play. The metal powder is reclaimed and reintroduced into the crucible as metal scrap, thereby completing the cycle. This approach epitomizes the essence of the circular economy, mitigating waste generation and fostering environmental stewardship.
The lifecycle of metal powder is a technological marvel on its own; it constitutes a narrative of conscientious industrial practices, seamlessly melding innovation with a steadfast commitment to sustainability. As we navigate the intricacies of metallurgical processes, we chart a course towards a future characterized by efficiency, environmental consciousness, and boundless potential. The journey of metal powder serves as a guiding beacon, illuminating the path towards a harmonious coalescence of industry and ecology.
Shenzhen Yujiaxin Technology Co., Ltd., as a prominent player in the metal powder processing industry, has been deeply rooted in the field of metal powder metallurgy since its inception, striving to become a leader in innovation and quality. The company specializes in the entire process technology of metal powder preparation, modification, forming, and sintering, encompassing the research and production of various metal powder metallurgy materials such as iron-based, copper-based, aluminum-based, and nickel-based powders. By adopting advanced powder metallurgy techniques, including Metal Injection Molding (MIM), Powder Metallurgy Pressing (PM), and Laser Cladding, Yujiaxin Technology not only enhances the precision and performance of metal components but also significantly shortens production cycles and reduces manufacturing costs. With a focus on integrating technological innovation with customer needs, the company provides high-performance, customized metal powder metallurgy solutions for numerous industries, including automotive, aerospace, electronics and information, medical devices, and more. This truly realizes a one-stop service from raw materials to finished products, highlighting its core competitiveness and professional status within the metal powder metallurgy supply chain.
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Skerlin Fang
Explore the challenges and solutions of appearance quality in MIM production
In the field of metal injection molding (MIM) and powder metallurgy production, the appearance quality of parts is not only the focus of customers, but also a key yardstick for measuring the stability of production processes and product reliability. However, due to the complexity of the process, appearance defects occur from time to time, which has become a major challenge in the production process. Next, through this blog, I will discuss with you several common appearance defects, the reasons behind them, and practical solutions.
1. Rough surface: a stumbling block in the process journey
If the surface of the part appears rough and uneven, it will not only affect the visual beauty, but also may weaken its overall performance. This is usually due to uneven powder particle size, poor mold quality or improper injection parameters.
Improvement method:
-Choose finer and more uniform powder raw materials to ensure a solid material foundation.
-Carefully adjust the injection pressure and speed to allow the material to flow freely in the mold to form a smooth surface.
-Regular cleaning and polishing of the mold is essential, because the “appearance” of the mold directly determines the “face” of the part.
2. Uneven shrinkage: an invisible threat to precision
If the sintered parts are uneven in size or deformed, it may be caused by uneven material mixing, too high sintering temperature or unreasonable mold design.
Improvement method:
-Ensure that the powder and binder are fully mixed to reduce internal stress
-Accurately control the heating rate and holding time during sintering, and treat each product like a treasure.
-Consider the uniformity of wall thickness when designing the mold to ensure that the parts remain stable during the sintering process.
3. Cracking: a hard flaw that cannot be ignored
Cracks that appear in parts during degreasing or sintering are often caused by the accumulation of internal stress or the influence of residual gas.
Improvement method:
-Carry out degreasing treatment in stages, starting from low temperature and gradually releasing internal stress.
-Ensure that the degreasing process is thorough, especially for parts with complex shapes, to ensure that the gas exhaust channel is unobstructed.
-Improve the injection process to avoid uneven filling and ensure the integrity of the internal structure of the parts.
4. Deformation: Accidents during sintering
If parts bend or deform after sintering, it may be caused by excessive temperature or insufficient support.
Improvement methods:
-Adjust the sintering curve to find the most suitable temperature range.
-Use sintering fixtures to provide support for complex parts to ensure that they maintain a stable shape in a high temperature environment.
-Optimize the mold demolding design to reduce shape deviation caused by stress concentration.
5. Black spots or spots: surface defects
These defects may be caused by material oxidation, mold contamination or impurities. Although small, they affect the overall appearance.
Improvement methods:
-Use high-purity powder raw materials to avoid oxidation and impurity contamination.
-Clean the mold regularly and strictly control the amount of release agent used.
-Improve the production environment, reduce the interference of dust and foreign matter, and keep the production area clean.
6. Color difference: the individuality of the process
The inconsistent color of the sintered parts is usually due to uneven material composition or improper control of the sintering atmosphere.
Improvement methods:
-Ensure that the raw materials are mixed evenly to make the parts consistent inside and outside.
-Adjust the sintering atmosphere, such as using a reducing atmosphere, to avoid excessive oxidation reaction.
-Regularly update the injection material to avoid performance fluctuations caused by material aging.
7. Flash: unnecessary troubles
Flash is the direct result of poor mold closure or excessive injection pressure, which increases the difficulty of subsequent processing.
Improvement method:
-Regularly inspect the mold to ensure tight and seamless closure.
-Adjust the injection pressure to the optimal value to ensure complete filling without overflow.
Shenzhen Yujiaxin Technology Co., Ltd., driven by innovation, uses cutting-edge titanium alloy metal powder injection molding technology to carefully create various medical devices and medical implant parts. We are committed to providing high-precision and high-reliability products to ensure the health and safety of every patient. Whether it is a complex pacemaker or a tiny dental implant, we can manufacture it accurately and perfectly match it. Choose Yujiaxin, choose trust and peace of mind.
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Skerlin Fang
Application of powder metallurgy in power tool parts
Against the background of the rapid development of the power tool industry, there is an increasing demand for high-performance, durable and affordable parts. Powder metallurgy (PM) technology is gradually emerging as an innovator in this field. The unique properties of metal powders allow manufacturers to create parts that meet the demanding standards of modern power tools. This article will delve into the unique advantages of powder metallurgy in power tool components and highlight its key applications.
Powder metallurgy, simply put, is a process of manufacturing solid metal parts by pressing and sintering metal powder. This technology allows manufacturers to precisely control the density, strength and dimensional accuracy of the final product, and is particularly suitable for producing complex shapes and designs that are difficult to achieve with traditional processing methods.
In the field of power tools, powder metallurgy shows significant advantages.
First, from a cost-effectiveness perspective, powder metallurgy significantly reduces material waste through near-net shape production and reduces the need for extensive machining, thereby effectively controlling production costs.
Second, parts manufactured through powder metallurgy often have superior mechanical properties, such as higher strength, hardness, and wear resistance, which are critical for frequently used power tools.
Additionally, powder metallurgy offers design flexibility, allowing manufacturers to create custom parts with internal cooling channels or complex geometries to meet specific tooling requirements.
Finally, PM components can also be optimized for power tool performance, such as by customizing porosity to enhance lubrication retention, thereby improving performance and service life in high-speed applications.
In power tools, the application of powder metallurgy is widespread and critical. Gear components are an important part of this. Powder metallurgy technology can produce high-precision and high-strength gears to ensure effective power transmission and long life of power tools such as electric drills and saws. In addition, components such as the stator and rotor in electric motors also benefit from powder metallurgy technology, which ensures that the motor performs optimally in the application by producing complex-shaped and high-density components to provide the required power and efficiency.
Cutting tools produced by powder metallurgy have also attracted much attention. Their high hardness and wear resistance allow the tools to maintain longer service life and sharpness under challenging conditions. At the same time, powder metallurgy is also used to make housings and protective cases for power tools. These parts are designed to be both lightweight and strong, providing protection while reducing the overall weight of the tool.
As the power tool market continues to grow and develop, powder metallurgy is becoming increasingly important as a key technology for producing high-quality components. With its cost-effectiveness, design flexibility and enhanced mechanical properties, powder metallurgy is changing manufacturers’ strategies in the production of power tool components.
Shenzhen Yujiaxin Technology Co., Ltd., as a leader in the field of powder metallurgy, specializes in the preparation, forming, and sintering of metal powders, committed to providing high-quality powder metallurgy products. We employ advanced atomization techniques to ensure uniform particle size and high purity of the metal powders, laying a solid foundation for subsequent pressing and sintering processes. Through precise mold design and optimization, we achieve one-time forming of complex-shaped parts, significantly enhancing production efficiency and product accuracy. During the sintering process, we utilize high-temperature vacuum furnaces to precisely control the sintering curve, ensuring material densification and optimal performance. Our powder metallurgy products, distinguished by their excellent mechanical properties, good dimensional stability, and cost-effectiveness, are widely used in various industries including automotive, aerospace, electronics, and more.
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