with PTFE (Polytetrafluoroethylene) bushings.

Self-lubricating steel bronze sintered bimetal bearing bushings.

Metal injection molding parts 

Powder metallurgy for many people should be very strange because in the design of electronic products used very little, even if useful to, are some standard accessories. For example, high-end smart phones in the SIM card holder, (is to take the card when you need to take a pin to the top, and then pop out of the drawer box, this is metal injection molding powder metallurgy manufacturing out). There is a common life, nail clippers, some of them are also made of powder metallurgy, and then there is the zipper head, gears, etc.. Usually relatively small metal parts, or small appearance of the metal parts used on the parts.
Due to the high cost of metal injection molding powder metallurgy manufacturing and processing, while technology continues to progress, many small parts can be replaced with zinc alloy or aluminum alloy and other die-casting metal. But metal injection molding powder metallurgy still has its advantages, for example, stainless steel powder metallurgy, polished to reveal the original color, can be done for decades or even longer will not fade, this is not with electroplating can replace.
A. What is metal injection molding powder metallurgy?

Metal injection molding ( Metal injection Molding) is a kind of metal powder and its binder plasticizing mixture injected into the model of the molding method. It is to first mix the selected powder with the binder, then granulate the mixture and inject it into the desired shape. The polymer imparts its viscous flow characteristics to the mix, which contributes to the uniformity of forming, cavity filling and powder loading. After forming, the binder is removed and the skimmed blanks are sintered. Some sintered products may be subjected to further densification, heat treatment or machining. Sintered products not only have the same complex shape and high precision as those obtained by plastic injection molding, but also have physical, chemical and mechanical properties close to those of forged parts. This process technology is suitable for high-volume production of small, precision, three-dimensional shape complex and metal parts with special performance requirements.
Second, the technical characteristics of metal injection molding powder metallurgy.

Metal injection molding technology combines the advantages of powder metallurgy and plastic injection molding two technologies, breaking through the traditional metal powder molding process in the shape of the product limitations, while using the plastic injection molding technology can be high-volume, high-efficiency forming parts with complex shapes, becoming a modern manufacturing high-quality precision parts of a molding technology, with conventional powder metallurgy, machining and precision casting and other processing The advantages of conventional powder metallurgy, machining and precision casting processing methods are incomparable.
1, like the production of plastic products to produce small metal parts with complex shapes, suitable for the manufacture of small parts with complex geometry, high precision and special requirements usually weighing in (0.2-200g)
2, can be directly formed thin-walled structural parts, the shape of the product close to or meet the final product requirements, dimensional tolerances can generally be maintained at ± 0.10% to ± 0.30% level
3, compared with traditional machining, precision casting, the internal structure of the product is more uniform; compared with the traditional powder metallurgy pressing sintering, product performance is better, high dimensional accuracy, good surface finish (surface roughness up to Ra0.80 ~ 1.6μm), no need for re-processing or only a small amount of finishing
4, wide range of materials, products with high density (up to 95% ~ 99%), and uniform organization, excellent performance, can be carburized, quenching, tempering and other heat treatment
5, the product microstructure uniform, product density, strength, hardness, toughness, plasticity and other mechanical properties of high, stable product quality, high production efficiency, automation, large quantities, large-scale production
Note: When designing the structure, it can be designed in accordance with the structure of plastic products, and the thinnest thickness can be more than 0.3mm. Of course, the thinner the thickness, the poorer the strength of the product, do not think that the metal is very hard, a gentle wrench will be bent.

Metal injection molding powder metallurgy is suitable with those materials.

Metal injection molding technology is suitable for iron-based alloy steel, stainless steel, nickel-based alloy, tungsten alloy, cemented carbide, titanium alloy, magnetic materials, Kovar alloy, fine ceramics, etc.

Metal injection molding powder metallurgy manufacturing process.

The general process is divided into: powder making → mixing granulation (metal powder mixed with bonding agent) → injection molding → degreasing → sintering → post-treatment. Here before feeding the mixed powder into particles, and then to better injection molding.
1、Powder making
Powder making is the process of making raw materials into powder, the commonly used powder making methods are oxide reduction method and mechanical method.
A, oxide reduction method is a solid or liquid reducing agent to reduce the metal oxide made of powder.
B, mechanical method is the use of ball milling or the use of power (such as airflow or liquid flow) so that the metal material between the pieces of collision, friction to obtain metal powder method
2、Mixing and granulation
Mixing is a variety of required powder mixed in a certain proportion, and homogenize it into a billet powder process. Divided into dry, semi-dry and wet three, respectively, for different requirements.
A、Semi-dry type is used for the situation where the density of each component is different and the requirement of uniformity is high, and a small amount of liquid (such as oil) is added when mixing.
B. Wet mixing with a large amount of volatile liquid (such as alcohol), accompanied by ball milling, to improve the uniformity of the mixture, increase the contact area between the components and improve the sintering performance. In order to improve the formability of the mix, plasticizer is added to the mix.
C. Dry type is used in the case where the density of each component is similar and the mixing uniformity is not high.
3、Injection molding
Forming is the process of mixing a homogeneous mixture, loaded into the press mold and pressed into a certain shape, size and density of the shape of the blank. The following two methods are commonly used for press molding.
A, heating pressure forming high temperature powder particles become soft, deformation resistance is reduced, with a smaller pressure can be obtained dense shape of the billet.
B, room temperature pressure forming in the mechanical pressure between the powder particles to produce mechanical phagocytic force and inter-atomic adsorption, thus forming a cold welding bond, made of the shape of the blank. The advantage is that there is no special requirement for equipment and mold material, and the operation is simple; the disadvantage is that the bonding force between powder particles is weak, and the billet is easy to be damaged, and the billet is formed at room temperature, so it needs to apply a large pressure to overcome the process hardening phenomenon caused by plastic deformation of powder particles. In addition, the density of the pressure-formed billet at room temperature is low, so its porosity is larger.
4、Sintering
Sintering is through baking, so that the shape of the billet particles between the diffusion, fusion welding, recrystallization and other processes, so that the powder particles firmly welded together, so that the pores reduce the density increases, and finally get “crystal bond”. So as to obtain the required process with certain physical and mechanical properties.
5、After treatment
Powder metallurgy products can be used directly after sintering, but when the performance requirements of the products are high, it is often necessary to post-treatment. The following post-treatment methods are commonly used.
A, steam treatment of iron-based parts in 500-600 ℃ water vapor treatment, so that the internal and external surfaces of the parts to form a layer of hard and dense oxide film, thereby improving the wear resistance of the parts and prevent the parts from rusting. (for mechanical parts, such as gears, etc.)
B, vulcanization treatment will be placed in 120 ℃ molten sulfur tank parts, after ten minutes to take out, and under the protection of hydrogen gas and then heated to 720 ℃, so that the surface pores of the parts to form sulfide. Sulfide treatment can greatly improve the wear reduction of parts and improve processing performance.
C, shaping the sintered parts into a similar structure with the press mold shaping mold, in the press and then a press shape, in order to improve the dimensional accuracy of the parts and reduce the surface roughness of the parts, used to eliminate the trace deformation caused in the sintering process.
D, oil infiltration parts into 100-200 ℃ hot oil heavy or under vacuum so that oil penetration into the pores of powder parts in the process, after oil immersion parts can improve wear resistance, and can prevent parts from rusting. (For mechanical parts, such as gears, etc.)
E, polishing plating treatment, the product is placed on the polishing jig, manual or mechanical polishing, so that the surface becomes bright, and then cleaned, and then plating treatment.
Note: The general process is to mix the metal powder material with the binder according to the proportion, then injection molding, then sintering, and then post-treatment. It should be noted that after the sintering is completed, the product will have deformation, then it needs to do the shaping mold to shape.

Manufacturing a sintered bronze oil-filled bearing bush part involves multiple stages. Here is a general summary of the processes involved:

1. Material Selection: The first step involves selecting the appropriate material for the bearing. For sintered bronze oil-filled bearings, a specific kind of bronze powder is usually selected. The selected bronze powder is typically rich in copper and tin.
2. Powder Mixing: The bronze powder is mixed with a binding agent. This agent will help the powder particles stick together during pressing. This mix is then heated slightly to improve its formability.
3. Compaction: The heated mix is placed in a die that matches the shape of the desired bearing. The mix is then compacted under high pressure to create a “green” part. This green part has the shape of the final part, but is porous and not yet strong enough for use.
4. Sintering: The green part is heated in a controlled atmosphere furnace. The temperature is below the melting point of bronze, but high enough to cause the particles to bond together. The binding agent is also burned off during this process. The part shrinks during sintering, but maintains its shape. The result is a solid bronze part that is still porous.
5. Oil Impregnation: The sintered part is soaked in high-grade oil under vacuum. The vacuum causes the oil to be drawn into the pores of the part. This process imparts self-lubricating properties to the bearing.
6. Inspection and Finishing: The final part is inspected for quality and any necessary finishing processes are performed. This could include grinding or machining to achieve the final dimensions and surface finish.
7. Packaging and Shipping: The finished parts are then packaged and shipped to the customer.

Each of these steps requires careful control of the process conditions to ensure that the final part meets the required specifications. Any changes in these conditions can dramatically affect the performance of the final part.

The cost breakdown of manufacturing a sintered bronze oil-filled bearing bush using CuSn10 material is variable depending on a number of factors such as quantity of production, the specific processes used, labor costs, energy costs, etc. Here’s a general idea of how costs might break down:

1. Material Cost: This would include the cost of CuSn10 bronze powder, binding agent, and the oil for impregnation. The exact costs can vary based on market prices, but as of my knowledge cutoff in 2021, copper alloy powders generally cost anywhere from $10-30 per kilogram.
2. Production Costs: These include the costs of operating the equipment used for mixing, compaction, sintering, and oil impregnation. These costs can be variable based on the specific equipment used, the energy costs in your area, and how efficiently your processes are run.
3. Labor Costs: These are the costs of the workers who operate the equipment, perform quality control, and manage the overall process. These costs can vary widely based on location, skill level, and the efficiency of your operation.
4. Overhead Costs: These include costs such as rent or mortgage for the production facility, utilities, maintenance and repairs for equipment, administrative costs, etc.
5. Shipping and Packaging Costs: This includes the cost of materials for packaging the bearings, labor for packaging, and the cost of shipping to the customer.

Without specific data on the quantities being produced, the efficiencies of the processes, current material costs, labor rates, etc., it is impossible to provide an exact cost breakdown. You would need to gather this data and calculate the costs based on the specifics of your situation.

Please note that this is a simplistic breakdown and there might be other costs involved depending upon the specifics of the manufacturing setup, region, regulations, etc. For a more accurate and detailed cost breakdown, you might want to engage a manufacturing consultant or a cost accountant who specializes in manufacturing.

Applications of metal injection molding powder metallurgy.

Applications of metal injection molding powder metallurgy.

1、Computer and auxiliary facilities: such as printer parts, magnetic core, firing pin shaft pin, drive parts.
2, tools: such as gun drills, drill chucks, power tools, hand tools, wrenches and other parts used, milling cutter head, nozzles, etc.
3, household appliances: such as cases, watch chains, electric toothbrushes, scissors, fans, golf heads, simulation jewelry, cutter bits and other parts.
4, medical equipment parts: such as dental orthopedic frame, scissors, tweezers.
5, military ordnance parts: missile tail, gun parts, warheads, drug type cover, fuze with parts.
6, electrical parts: such as micro-motor parts, electronic parts, sensor parts, cell phones, with parts.
7, mechanical parts: such as cotton loosening machines, textile machines, sewing machines, office machinery and other types of small complex parts of machinery.
8, automotive, ship parts: such as clutch inner ring, rocker arm insert, fork set, distributor set, automotive airbag parts, automotive locks.
Note: Commonly used on cell phones in the side keys, card holder, notebook computers are often used in the spindle, etc.

Metal Injection Molding, a new powder metallurgy near net molding technology coming out of the plastic injection molding industry.

As we all know, plastic injection molding produces complex shapes at low cost…

Technology of powder metallurgy

Metal Injection Molding is a metalworking process by which finely powdered metal is mixed with a certain amount of binder material to form a “raw material” that can be processed by plastic processing equipment through so-called injection molds. This molding process allows complex parts to be molded in large quantities in a single operation. The end product is typically a component item used in a variety of industries and applications. the nature of metal injection molding feedstock flow is defined by a physics known as rheology. Current equipment capabilities require processing limited to a typical volume of 100 grams or less per “shot” into the mold. Rheology allows this “injection” to be distributed across multiple mold cavities, thus making it cost-effective to produce small, complex, high-volume products that would otherwise be quite expensive to produce by other or conventional methods. The various metals that can be implemented in metal injection molding feedstock are referred to as powder metallurgy, and these metals contain the same alloy composition as in industry standards for common and specialty metal applications. Subsequent conditioning operations are performed on the molded shape, where the binder material is removed and the metal particles are coalesced into the desired metal alloy state.

Sintered Bush: A Comprehensive Guide

Sintered bushings are an essential component used in a wide range of industrial applications. They are commonly used as bearings, guide bushings, and structural components. The sintering process involves compacting metal powders under high pressure and temperature, which creates a dense, solid material with excellent mechanical properties. In this article, we will explore the advantages of sintered bushings, their applications, and the materials used in their manufacture.

Advantages of Sintered Bushings

Sintered bushings offer several advantages over other types of bearings and bushings. Some of these advantages include:

1. Cost-effective: Sintered bushings are relatively inexpensive to manufacture, making them an economical option for many applications.
2. Self-lubricating: Sintered bushings have a porous structure that can retain lubricants, which reduces friction and wear between mating surfaces. This makes them ideal for applications where maintenance is difficult or where there is no possibility of adding additional lubrication.
3. High load capacity: Sintered bushings can withstand heavy loads and provide excellent support to rotating or oscillating shafts.
4. Corrosion resistance: Many sintered bushing materials have good corrosion resistance properties, making them ideal for use in harsh environments.
5. High temperature resistance: Some sintered bushing materials can withstand high temperatures, making them suitable for use in high-temperature applications.

Applications of Sintered Bushings

Sintered bushings are used in a wide range of applications, including:

1. Automotive: Sintered bushings are commonly used in engines, transmissions, and suspension systems.
2. Aerospace: Sintered bushings are used in aircraft landing gear, hydraulic systems, and other critical components.
3. Industrial machinery: Sintered bushings are used in heavy equipment, pumps, and other machinery.
4. Medical equipment: Sintered bushings are used in medical devices such as surgical instruments and implantable devices.

Materials Used in Sintered Bushings

The materials used in sintered bushings can vary depending on the application. Some of the most common materials include:

1. Iron-based materials: Iron-based materials such as iron-copper, iron-nickel, and iron-molybdenum are commonly used in sintered bushings. These materials offer good wear resistance and high load capacity.
2. Copper-based materials: Copper-based materials such as bronze and brass are also used in sintered bushings. These materials offer good corrosion resistance and high thermal conductivity.
3. Stainless steel: Stainless steel is used in sintered bushings that require high corrosion resistance and high-temperature resistance.
4. Ceramic materials: Ceramic materials such as alumina and zirconia are used in sintered bushings that require high wear resistance and low friction.

Sintered bushings are a versatile and cost-effective solution for a wide range of industrial applications. They offer excellent load capacity, self-lubrication, and corrosion resistance properties, making them ideal for use in harsh environments. The materials used in sintered bushings can vary depending on the application, with iron-based, copper-based, stainless steel, and ceramic materials being the most common. If you’re looking for a reliable and durable solution for your industrial applications, sintered bushings may be the right choice for you.

The manufacturing process for sintered bronze oil-filled bearing bushes, according to sintered bronze bearing standards, remains relatively the same as described before but with more precise guidelines and quality control measures. specific process of creating oil-impregnated sintered bronze bearings.

Material Selection: The choice of material would still be a specific type of bronze powder, typically CuSn10 for bronze bearings.

Powder Mixing and Compaction: The bronze powder is mixed with a specific binding agent according to sintered bronze bearing standards and then compacted under high pressure to create a “green” part. The green part is not yet strong enough for use but is shaped according to the desired final product.

Sintering: The green part is then heated in a controlled environment furnace. The temperature and heating process are closely controlled to Oilite® standards to ensure proper sintering and bonding of the bronze particles, resulting in a strong and porous bronze part.

Oil Impregnation: The sintered part is soaked in high-grade oil under vacuum. This step is crucial for sintered bronze bearing bearings as they are renowned for their self-lubricating properties. The oil impregnation process is rigorously controlled to ensure that the oil is drawn into the pores of the part correctly.

Quality Control and Finishing: The final part is subjected to stringent quality control measures and any necessary finishing processes. This may involve precision machining to ensure that the final part adheres to the exact specifications of sintered bronze bearings.

Packaging and Shipping: Finally, the finished parts are packaged according to sintered bronze bearing standards and shipped to customers.

This process would be carried out in a manufacturing environment that meets sintered bronze bearing stringent quality

Sleeve bearings, also known as bushings, are essential components in many machines, such as blenders and electric tools, which reduce friction and allow for smooth movement. The two terms, “sleeve bearings” and “bushings,” are often used interchangeably in the world of machinery.

Among the various types of sleeve bearings, sintered bronze bushings are especially useful. They are created through a process known as sintering, where bronze powder is heated below its melting point until the particles bond together. This results in a porous material that is ideal for oil impregnation.

Oil-impregnated bronze bushings, or self-lubricating bushings, are thus a subcategory of sintered bronze bushings. During the manufacturing process, these sintered bushings are soaked in high-quality oil. This fills the material’s microscopic pores, creating a reservoir of lubricant within the bushing itself.

When the bearing is in use, the heat and friction of operation cause the oil to seep out of the pores, lubricating the interface between the bearing and the shaft. This creates a slick surface that allows the parts to move smoothly with minimal friction.

This self-lubrication mechanism is what makes these bearings “maintenance-free.” They do not need additional lubrication during their lifetime, reducing both maintenance time and costs. In addition, they tend to be more durable and have a longer lifespan compared to bearings that need regular lubrication.

These oil-impregnated bronze bushings are particularly ideal for applications like blenders and electric tools, where consistent, reliable, and smooth operation is crucial. They contribute to extending the life of these appliances by reducing wear and tear, minimizing noise, and enhancing overall performance.