Study on Metal-Ceramic Composite and Bonding using Powder Injection Molding Technology

Abstract

Multi-material components have an economic advantage as well as allowing the combination of properties of two materials compared to single material components. Therefore, the need for dissimilar materials bonding is more increasing. In the recent industry, small and complex-shaped multifunctional components have been increasingly demanded. Thus, in an effort to achieve these needs, metal/ceramic bonding using powder injection molding technology was studied in this thesis. Here, mixtures of metal and ceramic powder were also introduced to present the enhancement of bonding. In this regard, powder injection molding of metal/ceramic composite was first investigated by examining the properties of each material on the entire PIM process. The feedstocks and composites showed their unique characteristics, and no particular trend was observed with vol% of ceramic powder. As a result, the metal/ceramic composites can be applied to the parts with the required properties. Thereafter, the systematic experimental study for metal/ceramic bonding was established. In each PIM process, the factors that make the bonding difficult, and solutions were addressed in detail. Based on the optimized process, 17-4PH SS/3MYSZ bonding and 17-4PH SS/composite bonding were accomplished. After that, for 17-4PH SS/3MYSZ bonding, the interlock of two materials and interdiffusion of Cr and Zr at the interface were confirmed as the main mechanisms. In 17-4PH SS/composite bonding, it was the crucial reason to combine 17-4PH SS particles and 17-4PH SS particles in the composite. With the established process, 17-4PH SS/3MYSZ surgical forceps were successfully fabricated as a new application. It achieved the desired performance showing that no damage from the zirconia side at tissues. In addition, a finite element analysis platform was built for co-sintering simulation. The experiment and simulation results agreed well. Therefore, it can be utilized to determine the co-sintering temperature and optimal heating cycle to minimize the time-consuming sintering experiment.