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5.Production of Automotive Components

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Ahmed Barihsina
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11 views109 pages

5.Production of Automotive Components

Uploaded by

Ahmed Barihsina
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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School of Aerospace &

Automotive
Engineering

Dr.Rajesh Ravi
PRODUCTION OF School of Aerospace
&Automotive Engg,
AUTOMOBILE
Universite Internationale de
COMPONENTS Rabat-11103.
PISTON MANUFACTURING
CYLINDER
BLOCK
PISTON RING
CAM SHAFT
VALVES
VALVE SEAT
VALVE SPRING
CYLINDER HEAD
CRANK SHAFT
CONNECTING ROD
TURBO CHARGER
EXHAUST MANIFOLD
Powder Injection Molding (PIM)
The Process
Mixing

Very fine metal or ceramic


powders are mixed with
thermoplastic polymer (known as
the binder) to form a
homogeneous mixture of
ingredients that is pelletized and
directly fed into a injection
molding machine. This pelletized
powder-polymer mixture is known
as feedstock.
Injection

In this process, the feedstock is heated to


melt the binder content in order to form
the desired component geometry. The
molded part is known as the green part.
Debinding

The polymeric binder is removed from green


part by thermal heating to approximately 400°C
or 752°F. The result is known as the brown part
that still contains its original geometry and size.
Sintering

In this process, the brown part is heated to


approximately 85% of the material's melting
temperature, allowing densification and
shrinking of the powder into a dense solid
with the elimination of pores. The sintered
density is approximately 98% of theoretical.
The end result is a net shape or near net-
shape metal or ceramic component, with
properties similar to that of bar stock.
Powder Injection Molding (PIM)

Powder injection molding (PIM) is a manufacturing solution for producing intricate parts
in medium to high volumes (10,000 to over 2,000,000 parts annually) using fine (<20
μm) metal or ceramic powders.

PIM is capable of transforming complex concepts & designs into high precision, high
final properties, and net-shaped products from a wide range of materials such as carbon
steels, low alloy steels, stainless steels, low expansion alloys (kovar and invar), tool
steels, soft magnetic alloys, super alloys, to conductive materials (copper), and
ceramics.

PIM is well suited for parts weighing from 0.1gm to 250 gm. Cross sections are typically
less than 0.25 in. (6.35 mm). However, parts are not restricted to this combination of
mass and cross section. Tolerances are on the order of ±0.3 to 0.5%, albeit specific
dimensions can be held as close as ±0.1%.
Materials
Category Examples of materials processed
by PIM
Carbon Steel
1010, 1060

Low Alloy Steel Fe-2Ni, Fe-2Ni-0.5C, Fe-2Ni-0.5C-


HT, Fe-8Ni, SAE 4650
316L, 430L, 440C, 440C-HT, 17-
Stainless Steel
4PH, 17-4PH -HT, HK 30, SUS
420J2, SUS 310
Low Expansion Alloy
Kovar, Invar

Tool Steel
M2

Soft Magnetic Alloy Pure Iron, Fe-3Si, Alloy 52,


Permendur, Permalloy
Super Alloy
Inconel 718, Hastelloy X, F75

Heat Conductive Material


Copper, W-15Cu

Heavy Alloy
90Fe-Ni, 92W-Fe-Ni, 95W-Fe-Ni

Ceramic
Alumina, Zirconia, Spinel
Advantages

PIM enables processing of high melting point metals and ceramics with the following benefits:

Attractive cost savings

Wide latitude of part shape, sizes (0.1g to 250g) and design

Ability to combine functions and eliminate sub-assemblies

Good dimensional control with close tolerances of ±0.5%

Net shape production, eliminating or minimizes machining

Wide range of available alloys, composites and properties

Cost efficient for moderate-to-high production volume

Suitable for intricate and complex geometries

High material density and strength

Design flexibility

Produce good surface finishes


Comparison of PIM to conventional metal-forming processes

The quest for industrialization and automation has seen the development of
various manufacturing technologies.

While traditional methods like machining, stamping, forging, casting and


powder metallurgy remain important, PIM is fast becoming an integral
process in metal forming.
Powder
Parameters PIM Casting Machining Stamping
Metallurgy

Density 98% 86% 98% 100% 100%

Tensile
High Low High High High
Strength

Surface Finish High Medium Medium High High

Miniaturization High Medium Low Medium High

Thin Wall
High Medium Medium Low High
Capability

Complexity High Low Medium High Low

Design
High Medium Medium Medium Low
Flexibility

Production
High High Medium Med-High High
Quantity

Range of
High High Med-high High Medium
Materials

Affordability High High Medium Low High

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