September
1995
Volume 1 • Number 2
Technical
Information Search: Free Information On Powder Injection Molding
Available
Powder
injection molding (PIM) is an attractive option for manufacturing
precision components of complex geometry because it combines the
manufacturing advantages of plastic injection molding with the
mechanical, magnetic, electrical, thermal, and corrosion properties
of metals and ceramics.
PIM
is gaining wide acceptance because the introduction of "off the
shelf" feedstocks by companies such as Advanced Metalworking Practices
and BASF Corp. has made it easier for injection molders to access
PIM technology.
The
PIM process in a nutshell: A feedstock is a mixture of powder
and binder. The powder can be of many different materials, sizes
and shapes, depending on the properties desired. The binder system
is developed so that it holds the powder together but is easily
removed during the debinding and sintering operations that follow
injection molding.
After
molding, the "green" parts are very fragile. A thermal and/or
solvent debinding step is used to remove the majority of the binder;
control of this process is critical. If too little binder is removed,
the parts will crack during sintering. If too much binder is removed,
you're left with a pile of powder.
Next,
the parts are sintered by raising their temperature to a point
where atomic motion causes the powder metal particles to fuse.
Ideally, sintering should be performed in a vacuum; at the very
least it must be done in an atmosphere that is soluble in the
sintering material to prevent gas from becoming trapped in the
part.
Poor
control of previous operations often doesn't become evident until
sintering. Varying powder particle size distribution can cause
fluctuations in shrinkage and mechanical properties of the part;
inconsistent temperature or packing of the parts during molding
shows up as cracks at weld lines. Removing too little binder can
also result in cracks.
There
are several resources for injection molders interested in developing
PIM capabilities. Penn State's PIM Consortium employs a team of
world-class experts; the National Center for Excellence in Metalworking
Technology (NCEMT) is available for private contract research.
The Metal Powder Industries Federation cosponsors an annual PIM
symposium and has published several books on the technology. And
BASF Corp. has begun to market a turnkey PIM system.
A
complete technical information search on PIM has been conducted
by Bradley Johnson, a lecturer of engineering at Penn State Erie
and a PTDC-affiliated faculty member. Free copies of the report
can be obtained by calling the PTDC at (814) 898-6345 or writing
to the Center at Penn State Erie, Station Road, Erie PA 16563-0101.
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Education
Opportunity: Manufacturing Videoconferences Have Country's Highest
Market Penetration; Will Be Offered Again In '95-'96
The
National Technological University (NTU) videoconferences beamed
to Penn State Erie and the PTDC last year boasted the highest
penetration of small manufacturers of any downlink site in the
country--attendance was four times better than that of our closest
competitor.
If
you didn't make any of last year's videoconferences, you have
a second opportunity. NTU's Modern Manufacturing: The National
Videoconference Series for Successful Small Firms will again be
presented each month at Penn State Erie. These three-hour interactive
sessions allow you to telephone the presenters for real-time discussion;
local wrap-around sessions add value by allowing local manufacturers
and manufacturing experts to offer their thoughts on the day's
topic.
The
videoconference Production and Shop Floor Management I: Scheduling
in a Small Job Shop, will be held on Wednesday, Sept. 13, from
8:30 a.m. until noon, followed by lunch. Manufacturing consultant
Roland Raeker will discuss identifying the best inventory control
system for your company, and present illustrative case studies
featuring Wichita Tool Co. Inc. and SOR, Inc.
On
Wednesday, Sept. 27, Raeker will continue with Part II
of the program, which focuses on the next generation of scheduling
systems and customizing alternatives for small manufacturing environments.
Case studies will feature the successful implementation of inventory
scheduling programs at SOR and Pitsco, Inc. Through one or both
of these presentations, small and mid-sized manufacturers can
learn to identify the best system for their company by developing
an understanding of the key elements of an effective schedule;
learning how to analyze the advantages and disadvantages of various
approaches and their application to manufacturing; and by seeing
approaches that have worked well for case study companies. Cost
of the two teleconferences is $100, including a continental breakfast,
box lunch, and course materials.
Continuous
Improvement I: The New Philosophy and Management's Leadership
Role will be offered on Wednesday, Oct. 11; this videoconference
discusses the changes in process and strategies that can help
manufacturers move from survival to success.
Equipment
Retrofitting and Re-Use: Extending the Life of Your Equipment
will be held on Wednesday, Oct. 25. This videoconference can help
manufacturers avoid expensive equipment purchases by suggesting
methods of repair and retrofit that can return components to their
original level of performance.
Continuous
Improvement II: Ten Strategies for Improving Processes offers
solid strategies for studying and streamlining the manufacturing
process illustrated with case studies. It will be held on Wednesday,
Nov. 8.
NTU
videoconferences are sponsored by the National Institute of Standards
and Technology (NIST) and produced by the NIST/Mid-America Manufacturing
Technology Center (MAMTC). They are presented locally by the PTDC,
the Pennsylvania Technical Assistance Program (PENNTAP) and the
Northwest Pennsylvania Industrial Resource Center. For detailed
information about any program, fee information, or to register,
call PENNTAP at (814) 898-6139 or FAX (814) 898-6006.
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Training
Opportunity: Injection Molding Training To Be Offered On Demand
Beginning
this fall, the PTDC will offer injection molding training on demand
for interested employers. This mix of classroom and laboratory
experiences is generally conducted over a three-day period, but
the schedule can be tailored to meet an employer's needs. Molding,
mold set up, quality control, mold design, tool making, and part
design will be addressed, again with the employer's choice of
emphasis. By the end of the training period, it is expected that
participants will understand the requirements of an injection
mold; become familiar with the behavior of plastics, and use that
knowledge to troubleshoot problems; understand the relationship
between product design, tool design, processing, and part characteristics,
and how that relationship affects quality; and master the steps
to setting up a mold. These injection molding training modules
offer new employees a solid introduction to the injection molding
process; experienced employees can also benefit from formal training
and explanation of the principles upon which injection molding
operates.
Anyone
interested in learning more about tailored injection molding training
should contact Mike McDavid, Penn State Erie Continuing and Distance
Education Representative, at (814) 898-6103.
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Recycling
Videoconferencing November 1, 1995
Penn
State Erie will be a downlink site for the PA Department of Environmental
Resources' Plastics Recycling: Meeting the Demand live videoconference
on Wednesday, Nov. 1 This two-hour interactive seminar will discuss
all facets of creating a cost-effective supply of quality recycled
plastics. For more information, call Jean McGrath, assistant director,
Continuing and Distance Education, at 1-800-252-3592.
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Visit
Us At The K-Fair
The
PTDC will be represented at this year's K-Fair to be held Oct.
5-12 in Dusseldorf, Germany. Please stop by Pennsylvania's booth,
which will be located in Hall #5, Booth USA A-12, #7.
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Memo
To Manufacturers: No Fear
Lincoln
once marketed a new car with the slogan "It's nothing to be afraid
of." I feel the same way about research and development.
Many
manufacturers, particularly small manufacturers, don't engage
in research that can help them improve their product, process,
or efficiency. Some of their reasons are valid: No research staff,
and not enough work to justify hiring one. The overhead is too
high. There's no money for an in-house stereolithography machine,
or process simulation workstation, or computer-aided engineering
software. Or, my favorite reason to forego research: "It's a time
thing." I worry that other manufacturers are held back by fear
of the unknown. To them I repeat: It's nothing to be afraid of.
From
January 2 to May 31 of this year, the PTDC had contact with 156
companies in Pennsylvania and Ohio. We made 88 site visits, and
discussed 166 projects. Free help was given on 125 of those projects;
contracts for technological assistance were entered into on 47
of them. The total price of the contracts was $108,000, for an
average of $3,200 per project. How many manufacturers can not
afford to make a better product for $3,200?
I
can allay the fears anyone might have about doing business with
the PTDC. There's no red tape; the majority of our projects are
completed within one week. It's inexpensive, because our overhead
is spread over many projects. And unlike an in-house researcher,
you can use our services, then leave us idle until the next project,
whether that's a month or a year down the road. We're professional,
and confidential: we like to share our successes, but if your
project is proprietary, we'll keep a lid on it.
If
you have an idea for optimizing a part, a product, or a process,
but aren't sure where to go with it , we have the time, the people,
and the capacity to help you turn good ideas into good business.
That's all research really is-- making truth out of theory.
On
a related note: Helping us in our quest to help you is the
Cleveland Advanced Manufacturing Program, better known as CAMP.
Since 1984, CAMP has helped regional manufacturers find affordable
and effective answers to their technology improvement issues.
Whether you are located in Pennsylvania or Ohio, CAMP can help
you find a "better way" to do business.
- William
Roche, Director
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