Properties of MIM 4140 Alloy After Injection Molding and Sintering
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The document discusses the properties and results of testing MIM 4140 alloy after injection molding and sintering, including recommendations for manufacturing mold parts and techniques. It highlights the casting method's efficiency in producing complex parts with notable hardness, accuracy, and low surface roughness, particularly after heat treatment. Additionally, the document outlines the necessary parameters for injection molding, such as pressure, temperature, and design considerations to ensure quality and durability.
![International Journal of Innovation Engineering and Science Research
Open Access
Volume 2 Issue 1 January 2018 10 | P a g e
ABSTRACT
Properties of MIM 4140 Alloy After Injection
Molding and Sintering
Denis Chemezov
Vladimir Industrial College
Vladimir, Russian Federation
Testing results of a multi-cavity mold for injection molding of MIM 4140 alloy are presented in the article.
Recommendations for manufacturing of forming parts of the mold were given. Based on an implemented
technological process of casting and subsequent laboratory researches an information was obtained about the
condition of a casting (hardness on Super-Rockwell, shrinkage and quality of a surface layer of material before
and after heat treatment). Calculated overall dimensions of the forming parts of the project mold will allow making
forecast of shrinkage of MIM 4140 alloy after injection molding.
Keywords – a casting, a mold, MIM 4140 alloy, a surface layer, injection molding.
I. INTRODUCTION
It is possible to obtain the small parts of a complex configuration by widespread methods of
processing. Mechanical processing of these parts leads to increasing of implementation time of an
operation (at compliance of high dimensional accuracy), range of standard and special cutting tools,
and in more cases it is used an unrational workpiece and etc. Casting [1] reduces manufacturing time
of these parts. However, difficulty of formation holes of the small diameter in the parts and not high
accuracy of casting leads to restriction of the use this method in production. For implementation of all
technical requirements for manufacturing of the described parts in serial production, rationally to select
the technology of filling metals into a mold under pressure by injection method with subsequent
sintering process of the obtained casting [2, 3]. MIM technology allows to obtain the finished parts of
different assignment from alloys based on iron (low-alloy steel, corrosion resistant steel, tool steel,
special steels), non-ferrous alloys (alloys of copper, heavy metals, hard alloys, light metals) and
ceramic materials. The part manufacturing by means of MIM technology and its quality control are
ensured by designing of tooling (the mold), selecting of the composition of initial mixture and
determining of the material properties.
II. MATERIAL AND METHOD
The some properties of material of the one-type castings obtained by MIM technology were exposed
by the research.
The manufactured casting has the shape of a body of rotation with the blind central hole. On the outer
diameter of the casting by injection molding an area with a radius output is formed. The outer
diameter of the casting is performed in a form of a cone. The drawing of the casting with diametric,
linear and angular sizes is presented in the Fig. 1.
Fig. 1. The drawing of the part “Plunger”.](https://image.slidesharecdn.com/911425944-181225110000/85/Properties-of-MIM-4140-Alloy-After-Injection-Molding-and-Sintering-1-320.jpg)
![Chemezov, D “International Journal of Innovation Engineering and Science Research”
Volume 2 Issue 1 January 2018 11 | P a g e
Unspecified tolerances in the drawing of the part were taken ±0.02 mm.
The castings were made from MIM 4140 alloy (low-alloy) [4]. Alloy contains 0.2 – 0.3% of
molybdenum, 0.3 – 0.5% of carbon, 0.8 – 1.2% of chromium, 0.6% of silicon, 1.0% of manganese and
rest it is iron. Density of material is 7.5 g/cm3
, ultimate strength – 1654.74 MPa, yield strength –
1241.06 MPa, elongation – 5%, Young's modulus – 203395.33 MPa, Poisson's ratio – 0.28,
unnotched Charpy impact energy [5, 6] – 74.5701 N·m.
Offset of the parting line of the mold is allowed no more than 0.1 mm. Number marking of the each
cavity must perform by depth of 0.2 mm. The drawings of the forming parts of the mold are presented
in the Fig. 2 and 3.
Fig. 2. The drawing of the part “Insert 149-13” (the forming part of the mold).
Fig. 3. The drawing of the part “Insert 149-14” (the forming part of the mold).](https://image.slidesharecdn.com/911425944-181225110000/85/Properties-of-MIM-4140-Alloy-After-Injection-Molding-and-Sintering-2-320.jpg)
![Chemezov, D “International Journal of Innovation Engineering and Science Research”
Volume 2 Issue 1 January 2018 12 | P a g e
The part "Insert" is made from alloy tool die steel T30402. For implementation of casting process, the
part is exposed to heat treatment to hardness of 58...62 HRC. Surface roughness of the gating
system should be 0.63 µm. The remaining technical requirements for manufacturing of the part are
according to GOST 27358-87.
Roughness of the forming surfaces obtained by electrical discharge machining should be 0.63 µm.
Preliminary quality control of the assembly mold was carried out by mating of the three-dimensional
models of the parts in the unit. The general view of the mold is presented in three-dimensional
formulation (Fig. 4). The assembly process of the multi-cavity mold for injection molding of MIM 4140
alloy is presented in the Fig. 5.
Fig. 4. The three-dimensional model of the eight-cavity mold.
Fig. 5. The assembly process of the eight-cavity mold for injection molding of MIM 4140 alloy.
Manufacturing of the castings was performed on the injection molding machine Arburg Allrounder
270C 400-100 [7]. High reliability and repeatability of the injection molding machine allow to perform
casting of the parts with minimal deviations. The requirements for manufacturing of the castings and
the mold for injection molding are presented in the table 1.
TABLE I. THE REQUIREMENTS FOR MANUFACTURING OF THE CASTINGS AND THE MOLD.
Parameter Value
Release program of the parts 40000 pieces per year
Mass of the part 1.1 g
Calculated shrinkage of polymer material during molding
process of the part
18%
Molding temperature 180 °C
Pressure 1000 – 1700 kg/cm
2
Downtime under pressure 3 s
Molding cycle 35 – 60 s
Temperature of cooling liquid (air) 40 – 60 °С
Number of the mold cavities 8
Design of an inlet channel or a sprue tunnel
Operation mode of the mold automated
Requirements for material of the forming parts of the mold
hardness of the forming parts at least 60 HRC, high
wear resistance
Calculated guaranteed life of the mold 300000 cycles
Operations of flash trimming and sprues separation are not acceptable.](https://image.slidesharecdn.com/911425944-181225110000/85/Properties-of-MIM-4140-Alloy-After-Injection-Molding-and-Sintering-3-320.jpg)
![Chemezov, D “International Journal of Innovation Engineering and Science Research”
Volume 2 Issue 1 January 2018 13 | P a g e
III. RESULT AND DISCUSSION
Calculated shrinkage of the casting is achieved after material cooling in the mold. Required shrinkage
of the part is achieved after heat treatment (sintering). Accuracy of linear, diametrical and angular sizes
of the part is confirmed at measurement by measuring tools. Comparison of shrinkage of the castings
material before and after heat treatment is presented in the Fig. 6.
A B
Fig. 6. Shrinkage of the castings material after heat treatment (A) and before heat treatment (B).
The condition of the surface layer of the castings before and after heat treatment was determined on
the video-measuring microscope VP-6440 (United Kingdom) [8]. The microscope of this model is
characterized by a permissible absolute error of measurements of linear dimensions along the axes X,
Y and Z in the range ±(2.5 + L/150) µm (where L is a measured length in mm) and discreteness of
reference of linear measurements – 0.0005 mm. Working with the microscope was carried out at an
ambient temperature of 22 °C. The results are presented in the Fig. 7.
A C E
B D F
G I K
H J L
Fig. 7. The condition of the surface layer of the castings before heat treatment (A – F) and after heat treatment (G – L).
Magnification ×5.
After cooling of the casting in the mold it is observed high density of material. Before heat treatment,
the casting material is very brittle. After heat treatment, high density of material remains. On the
surface layer of the casting material microporosity is formed. Porosity in researched material of the](https://image.slidesharecdn.com/911425944-181225110000/85/Properties-of-MIM-4140-Alloy-After-Injection-Molding-and-Sintering-4-320.jpg)
![Chemezov, D “International Journal of Innovation Engineering and Science Research”
Volume 2 Issue 1 January 2018 14 | P a g e
casting increases resistance to cracking. Surface roughness of the casting material after MIM
technology is very low.
Hardness measurement of the casting material after heat treatment was performed by the method of
Super-Rockwell on the special hardness tester. Hardness (17 HRC) was obtained at indentation in the
casting material of the diamond cone (indenter) with an angle of 120° at the apex. Force of indentation
of the indenter was taken 150 kg.
IV. CONCLUSION
Thus, based on of the conducted analysis of the properties of MIM 4140 alloy after manufacturing of a
semi-finished product by injection molding and sintering, it is possible to draw the following
conclusions:
1. The configuration and manufacturing features of the mold are presented. Quality control of
assembly of the mold should be implemented by the three-dimensional model. Casting modes are
used for serial production of these castings. Recommended pressure at molding simultaneously eight
castings is 1500 kg/cm
2
. Temperature of the casting process of MIM 4140 alloy is similar to
temperature of the casting process of thermoplastics.
2. At average hardness of material, high dimensional accuracy and low roughness of the surfaces, the
casting (the part) is ready for assembly and subsequent operation. Porosity, formed after heat
treatment, provides the higher crack resistance of the casting material.
REFERENCES
[1] Precision Castings Division. Cost Drivers and Design Considerations for Investment Casting.
[2] R.M. German and A. Bose. Injection Molding of Metal and Ceramics. Princeton: MPIF, 1997.
[3] V. Raymond. Metal injection molding development: modeling and numerical simulation of injection with experimental
validation. Mémoire présenté en vue de l’obtention du diplôme de maîtriseès sciences appliquées, 2012. 122 p.
[4] Materials standards for metal injection molded parts. Published by metal powder industries federation, 2016. 39 p.
[5] ISO 148-1 Metallic materials – Charpy pendulum impact test – Part 1: Test method.
[6] H. Kurishita, H. Kayano, M. Narui, M. Yamazaki, Y. Kano and I. Shibahara. Effects of V-notch dimensions on Charpy
impact test results for differently sized miniature specimens of ferritic steel. Materials Transactions – JIM. Japan
Institute of Metals. 34 (11), 1993. pp. 1042–1052.
[7] Hydraulic ALLROUNDER's. Injection moulding machines for diverse applications. ARBURG GmbH, 2013.
[8] Optical instruments. Bowers group.](https://image.slidesharecdn.com/911425944-181225110000/85/Properties-of-MIM-4140-Alloy-After-Injection-Molding-and-Sintering-5-320.jpg)
Properties of MIM 4140 Alloy After Injection Molding and Sintering
- 1. International Journal of Innovation Engineering and Science Research Open Access Volume 2 Issue 1 January 2018 10 | P a g e ABSTRACT Properties of MIM 4140 Alloy After Injection Molding and Sintering Denis Chemezov Vladimir Industrial College Vladimir, Russian Federation Testing results of a multi-cavity mold for injection molding of MIM 4140 alloy are presented in the article. Recommendations for manufacturing of forming parts of the mold were given. Based on an implemented technological process of casting and subsequent laboratory researches an information was obtained about the condition of a casting (hardness on Super-Rockwell, shrinkage and quality of a surface layer of material before and after heat treatment). Calculated overall dimensions of the forming parts of the project mold will allow making forecast of shrinkage of MIM 4140 alloy after injection molding. Keywords – a casting, a mold, MIM 4140 alloy, a surface layer, injection molding. I. INTRODUCTION It is possible to obtain the small parts of a complex configuration by widespread methods of processing. Mechanical processing of these parts leads to increasing of implementation time of an operation (at compliance of high dimensional accuracy), range of standard and special cutting tools, and in more cases it is used an unrational workpiece and etc. Casting [1] reduces manufacturing time of these parts. However, difficulty of formation holes of the small diameter in the parts and not high accuracy of casting leads to restriction of the use this method in production. For implementation of all technical requirements for manufacturing of the described parts in serial production, rationally to select the technology of filling metals into a mold under pressure by injection method with subsequent sintering process of the obtained casting [2, 3]. MIM technology allows to obtain the finished parts of different assignment from alloys based on iron (low-alloy steel, corrosion resistant steel, tool steel, special steels), non-ferrous alloys (alloys of copper, heavy metals, hard alloys, light metals) and ceramic materials. The part manufacturing by means of MIM technology and its quality control are ensured by designing of tooling (the mold), selecting of the composition of initial mixture and determining of the material properties. II. MATERIAL AND METHOD The some properties of material of the one-type castings obtained by MIM technology were exposed by the research. The manufactured casting has the shape of a body of rotation with the blind central hole. On the outer diameter of the casting by injection molding an area with a radius output is formed. The outer diameter of the casting is performed in a form of a cone. The drawing of the casting with diametric, linear and angular sizes is presented in the Fig. 1. Fig. 1. The drawing of the part “Plunger”.
- 2. Chemezov, D “International Journal of Innovation Engineering and Science Research” Volume 2 Issue 1 January 2018 11 | P a g e Unspecified tolerances in the drawing of the part were taken ±0.02 mm. The castings were made from MIM 4140 alloy (low-alloy) [4]. Alloy contains 0.2 – 0.3% of molybdenum, 0.3 – 0.5% of carbon, 0.8 – 1.2% of chromium, 0.6% of silicon, 1.0% of manganese and rest it is iron. Density of material is 7.5 g/cm3 , ultimate strength – 1654.74 MPa, yield strength – 1241.06 MPa, elongation – 5%, Young's modulus – 203395.33 MPa, Poisson's ratio – 0.28, unnotched Charpy impact energy [5, 6] – 74.5701 N·m. Offset of the parting line of the mold is allowed no more than 0.1 mm. Number marking of the each cavity must perform by depth of 0.2 mm. The drawings of the forming parts of the mold are presented in the Fig. 2 and 3. Fig. 2. The drawing of the part “Insert 149-13” (the forming part of the mold). Fig. 3. The drawing of the part “Insert 149-14” (the forming part of the mold).
- 3. Chemezov, D “International Journal of Innovation Engineering and Science Research” Volume 2 Issue 1 January 2018 12 | P a g e The part "Insert" is made from alloy tool die steel T30402. For implementation of casting process, the part is exposed to heat treatment to hardness of 58...62 HRC. Surface roughness of the gating system should be 0.63 µm. The remaining technical requirements for manufacturing of the part are according to GOST 27358-87. Roughness of the forming surfaces obtained by electrical discharge machining should be 0.63 µm. Preliminary quality control of the assembly mold was carried out by mating of the three-dimensional models of the parts in the unit. The general view of the mold is presented in three-dimensional formulation (Fig. 4). The assembly process of the multi-cavity mold for injection molding of MIM 4140 alloy is presented in the Fig. 5. Fig. 4. The three-dimensional model of the eight-cavity mold. Fig. 5. The assembly process of the eight-cavity mold for injection molding of MIM 4140 alloy. Manufacturing of the castings was performed on the injection molding machine Arburg Allrounder 270C 400-100 [7]. High reliability and repeatability of the injection molding machine allow to perform casting of the parts with minimal deviations. The requirements for manufacturing of the castings and the mold for injection molding are presented in the table 1. TABLE I. THE REQUIREMENTS FOR MANUFACTURING OF THE CASTINGS AND THE MOLD. Parameter Value Release program of the parts 40000 pieces per year Mass of the part 1.1 g Calculated shrinkage of polymer material during molding process of the part 18% Molding temperature 180 °C Pressure 1000 – 1700 kg/cm 2 Downtime under pressure 3 s Molding cycle 35 – 60 s Temperature of cooling liquid (air) 40 – 60 °С Number of the mold cavities 8 Design of an inlet channel or a sprue tunnel Operation mode of the mold automated Requirements for material of the forming parts of the mold hardness of the forming parts at least 60 HRC, high wear resistance Calculated guaranteed life of the mold 300000 cycles Operations of flash trimming and sprues separation are not acceptable.
- 4. Chemezov, D “International Journal of Innovation Engineering and Science Research” Volume 2 Issue 1 January 2018 13 | P a g e III. RESULT AND DISCUSSION Calculated shrinkage of the casting is achieved after material cooling in the mold. Required shrinkage of the part is achieved after heat treatment (sintering). Accuracy of linear, diametrical and angular sizes of the part is confirmed at measurement by measuring tools. Comparison of shrinkage of the castings material before and after heat treatment is presented in the Fig. 6. A B Fig. 6. Shrinkage of the castings material after heat treatment (A) and before heat treatment (B). The condition of the surface layer of the castings before and after heat treatment was determined on the video-measuring microscope VP-6440 (United Kingdom) [8]. The microscope of this model is characterized by a permissible absolute error of measurements of linear dimensions along the axes X, Y and Z in the range ±(2.5 + L/150) µm (where L is a measured length in mm) and discreteness of reference of linear measurements – 0.0005 mm. Working with the microscope was carried out at an ambient temperature of 22 °C. The results are presented in the Fig. 7. A C E B D F G I K H J L Fig. 7. The condition of the surface layer of the castings before heat treatment (A – F) and after heat treatment (G – L). Magnification ×5. After cooling of the casting in the mold it is observed high density of material. Before heat treatment, the casting material is very brittle. After heat treatment, high density of material remains. On the surface layer of the casting material microporosity is formed. Porosity in researched material of the
- 5. Chemezov, D “International Journal of Innovation Engineering and Science Research” Volume 2 Issue 1 January 2018 14 | P a g e casting increases resistance to cracking. Surface roughness of the casting material after MIM technology is very low. Hardness measurement of the casting material after heat treatment was performed by the method of Super-Rockwell on the special hardness tester. Hardness (17 HRC) was obtained at indentation in the casting material of the diamond cone (indenter) with an angle of 120° at the apex. Force of indentation of the indenter was taken 150 kg. IV. CONCLUSION Thus, based on of the conducted analysis of the properties of MIM 4140 alloy after manufacturing of a semi-finished product by injection molding and sintering, it is possible to draw the following conclusions: 1. The configuration and manufacturing features of the mold are presented. Quality control of assembly of the mold should be implemented by the three-dimensional model. Casting modes are used for serial production of these castings. Recommended pressure at molding simultaneously eight castings is 1500 kg/cm 2 . Temperature of the casting process of MIM 4140 alloy is similar to temperature of the casting process of thermoplastics. 2. At average hardness of material, high dimensional accuracy and low roughness of the surfaces, the casting (the part) is ready for assembly and subsequent operation. Porosity, formed after heat treatment, provides the higher crack resistance of the casting material. REFERENCES [1] Precision Castings Division. Cost Drivers and Design Considerations for Investment Casting. [2] R.M. German and A. Bose. Injection Molding of Metal and Ceramics. Princeton: MPIF, 1997. [3] V. Raymond. Metal injection molding development: modeling and numerical simulation of injection with experimental validation. Mémoire présenté en vue de l’obtention du diplôme de maîtriseès sciences appliquées, 2012. 122 p. [4] Materials standards for metal injection molded parts. Published by metal powder industries federation, 2016. 39 p. [5] ISO 148-1 Metallic materials – Charpy pendulum impact test – Part 1: Test method. [6] H. Kurishita, H. Kayano, M. Narui, M. Yamazaki, Y. Kano and I. Shibahara. Effects of V-notch dimensions on Charpy impact test results for differently sized miniature specimens of ferritic steel. Materials Transactions – JIM. Japan Institute of Metals. 34 (11), 1993. pp. 1042–1052. [7] Hydraulic ALLROUNDER's. Injection moulding machines for diverse applications. ARBURG GmbH, 2013. [8] Optical instruments. Bowers group.