The original powder particle size used in metal powder injection molding is 2-15 μm, while the original powder particle size of traditional powder metallurgy is mostly 50-100 μm. The metal powder injection molding process has high product density due to the use of fine powder. The metal powder injection molding process has the advantages of traditional powder metallurgy process, but traditional powder metallurgy cannot achieve high degree of shape freedom. Traditional powder metallurgy is constrained by mold strength and filling density, and the mold shape is mostly two-dimensional cylindrical.
Traditional precision casting drying process is a very effective technology for producing complex-shaped products. In recent years, ceramic cores can be used to complete narrow and deep hole products. However, due to the constraints of the strength of the ceramic core and the flowability of the casting liquid, this process still faces certain technical difficulties. Generally speaking, this process is more suitable for large and medium-sized parts, and the process is more suitable for small and complex shaped parts.
Pressure casting process is used for materials with low melting point and good fluidity such as aluminum and zinc alloys. Due to material constraints, the strength, wear resistance, and corrosion resistance of the product are all constrained during this process. The process can process more materials. Although the precision casting process has improved its accuracy and complexity of products in recent years, it is still not as good as the wax removal process. Powder forging is an important progress in the large-scale production of connecting rods. However, overall, there are still problems such as heat treatment costs and die life in forging engineering that need to be further solved.
Traditional machining methods have recently improved their processing capabilities through automation, with great progress in both effectiveness and accuracy. However, the basic program still cannot complete the shape of the part without step-by-step processing (turning, planing, milling, grinding, drilling, polishing, etc.). The machining accuracy of machining methods is far better than other machining methods, but its completion of shape is limited by equipment and tools due to its low effective utilization of materials. On the contrary, the process can effectively utilize materials without constraints. In the manufacturing of small-shaped and difficult precision parts, the process has low cost, high efficiency, and strong competitiveness compared to machining methods. The technology is not to compete with traditional machining methods, but to make up for the shortcomings or defects in traditional machining methods in terms of technology or production. The technology can play its advantages in the field of parts processed by traditional machining methods. The technical advantages of the process in part manufacturing can form highly complex structural parts.
Powder injection molding technology uses injection molding machines to inject product blanks to ensure that the material is fully filled in the mold cavity, ensuring the realization of highly complex structured parts. In the past, in traditional machining technology, individual parts were first made and then assembled into parts. When using the technology, it can be considered to integrate them into a complete individual part, greatly reducing steps and simplifying the machining process. Compared with other metal processing methods, the product has a higher dimensional accuracy and does not require secondary processing or only requires a small amount of precision processing.