Simultaneous Acquirement of High Complication and functionality by New Metal Injection Molding Process.

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MIM process is hoped to be an advanced powder processing technique for near net shape forming the high density, high performance, and complicated pars. However, there still remains the issue of limitation in the shape and volume of MIM compacts because of using the die.In this study, as one of new approaches to improve the above problems in MIM process, MIM in-process joining of thin and hollow parts ***ing the exuded wax during solvent debinding step has been attempted to produce larger, more complicated and functional parts by combination of the same or different materials such as non-magnetic austenitic stainless steels (SUS304L, 316L) and martensitic stainless steel (SUS420J1) and pure iron with high magnetic flux density. Results obtained were as follows ;1) Perfect joined couples of the same (SUS304L/SUS304L, SUS420J1/SUS420J1) and different (SUS304L/SUS420J1) materials were obtained by MIM in-process joining (application of the exuded wax form green compacts during solvent debinding step).2) For the couple of iron and stainless steel compact, joining was difficult because of the different starting temperature of shrinkage. However, excellent joining was obtained by using stainless steel powder with fine particle size and vacuum sintering.3) For the couple of austenitic stainless steel and ferro-silicom compact, high functionality (magnetic non-magnetic ＆ (1.60 Tesla)) and perfect joint were obtained.