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Thesis (M.S.)--Oregon State University, 2009. / Printout. Includes bibliographical references (leaves 104-110). Also available on the World Wide Web.

A new material system was developed for fabricating the combustion engine of an unmanned aerial vehicle. The material system consisted of a mixture of nanoscale and microscale particles of silicon nitride. Magnesia and yttria were used as sintering additives. The powders were mixed with a paraffin binder system. The binder-powder was analyzed for its properties and molding attributes. The study involved several steps of the development and processing. These steps include torque rheometery analysis, mixing scale-up, property measurements of binder-powder, injection molding, binder removal, sintering, scanning electron microscopy analysis and mechanical properties measurements. Simulations of the injection molding process were conducted to assess the feasibility of manufacturing a ceramic engine and to determine its optimal process parameters. The model building required for the simulation was based on flow and solidification behavior data compiled for the binder-powder mixture. The simulations were performed using the Moldfow software package. A design of experiments approach was set up in order to gain an understanding of critical process parameters as well as identifying a feasible process window. Quality criteria were then analyzed in order to determine the optimal production parameters. The study resulted in the successful development of design parameters that will enable fabrication of silicon nitride engine components by powder injection molding. / Graduation date: 2012

Powder injection molding (PIM) is widely used to manufacture complex-shaped ceramic and metal components in high production volumes. In order to design and fabricate PIM components, it is important to know a number of material properties at different powder- polymer compositions. In this thesis, several predictive models for estimating rheological, thermal and mechanical properties as a function of powder-polymer mixtures were evaluated using experimental data obtained from the literature. Based on this survey, models were selected for predicting rheological, thermal and mechanical properties for aluminum nitride-polymer mixtures at various volume fractions of powder using experimental measurements of unfilled and filled polymers. The material properties were estimated for two aluminum nitride powder-polymer mixtures and used in mold-filling simulations. These results will provide new perspectives and design tools for identifying useful material compositions, component geometry attributes, and process parameters while eliminating expensive and time-consuming trial-and-error practices prevalent in PIM. / Graduation date: 2013

Powder injection molding (PIM) is a net fabrication technique that combines the complex shape-forming ability of plastic injection molding, the precision of die-casting, and the material selection flexibility of powder metallurgy. For this study, the design issues related to PIM for fabrication of thin-walled high-aspect ratio geometries were investigated. These types of geometries are typical to the field of microtechnology-based energy and chemical systems (MECS). MECS are multi-scale (sizes in at least two or more different length scale regimes) fluidic devices working on the principle of heat and mass transfer through embedded micro and nanoscale features. Stainless steel was the material chosen for the investigations because of its high-thermal resistance and chemical inertness necessary for typical microfluidic applications. The investigations for the study were performed using the state-of-the-art computer aided engineering (CAE) design tool, PIMSolver��. The effect of reducing part thickness, on the process parameters including melt temperature, mold temperature, fill time and switch over position, during the mold-filling stage of the injection molding cycle were investigated. The design of experiments was conducted using the Taguchi method. It was seen that the process variability generally increased with reduction in thickness. Mold temperature played the most significant role in controlling the mold filling behavior as the part thickness reduced. The effects of reducing part thickness, process parameters, microscale surface geometry and delivery system design on the occurrence of defects like short shots were also studied. The operating range, in which the mold cavity was completely filled, was greatly reduced as the part thickness was reduced. The single edge gated delivery system designs, with single or branched runners, resulted in a completely formed part. The presence of microchannel features on the part surface increased the possibility of formation of defects like short shots and weld-lines when compared to a featureless part. The study explored some typical micro-fluidic geometries for fabrication using PIM. The final aspect of this study was the PIM experiments performed using a commercial stainless steel feedstock. Experiments were performed to study the mold-filling behavior of a thin, high aspect ratio part and also to study the effect of varying processing conditions on the mold-filling behavior. These experiments also provided correspondence to the mold filling behavior simulated using PIMSolver��. The PIMSolver�� closely predicted the mold-filling patterns as seen in the experiments performed under similar molding conditions. The study was successful in laying down a quantitative framework for using PIM to fabricate micro-fluidic devices. / Graduation date: 2005

Neste trabalho, inicialmente, foram obtidos TPSs (amidos termoplásticos) com diferentes concentrações de amido e plastificantes, por processamento em câmara de mistura, com o objetivo de determinar formulações para estudo em extrusora reativa. As formulações de TPS que apresentaram os melhores resultados de torque reométrico foram as que continham 39%m/m de amido. Investigou-se a influência da velocidade da rosca na obtenção de TPS por extrusora reativa, e os resultados mostraram que este parâmetro teve pequena influência na estabilidade do amido termoplástico, sendo possível utilizar 150 rpm de rotação. Foram produzidas 5 blendas com razões de TPS:PEBDL variando de 30:70; 40:60; 50;50; 60:40 e 70:30 para o desenvolvimento de um sistema ligante para a injeção de alumina pelo processo de moldagem de pós (MPI), a partir das quais foi possível analisar a influência do TPS no PEBDL, através de análises de MEV, IF, TGA, DMA e propriedades mecânicas. Quanto maior a concentração de TPS nas blendas, mais heterogênea foi a morfologia observada por MEV e menor o módulo de armazenamento e de perda obtidos por DMA. Este comportamento foi similar ao encontrado pela análise de resistência à tração, que apresentou propriedades mecânicas pobres para elevadas concentrações de TPS. Foram escolhidas três blendas para testar como veículo orgânico em feedstocks de alumina, com carga de partícula sólida de 45%, 50% e 55%v/v de Al2O3. A carga crítica para o sistema ligante-partículas sólidas determinada por reometria de torque foi de 50%v/v de alumina. / In this work, TPSs (thermoplastic starch), with different concentrations of starch and plasticizers for processing in the mixing chamber, were obtained in order to determine formulations for study in a reactive extruder. The TPS formulations that showed the best results for the rheometric torque were those containing 39% w/w starch. The influence of the screw speed to obtain TPS in the reactive extruder was investigated and the results showed that this parameter had little influence on the stability of the thermoplastic starch, allowing the use of 150 rpm rotation speed. Five blends were produced, with TPS:LLDPE ratios of 30:70; 40:60; 50:50; 60:40 and 70:30, to develop a binder for alumina injection by the powder molding process (MPI). From these five systems it was possible to analyze the influence of TPS in LLDPE through SEM analyzes, MFI, TGA, DMA and mechanical properties. The higher the concentration of TPS in blends, more heterogeneous morphology was observed by SEM and the lowest storage and loss modulus were obtained by DMA. This behavior was similar to that found by analysis of tensile strength, which showed poor mechanical properties for high concentrations of TPS. Three blends were chosen for testing as an organic vehicle in alumina feedstocks, with solid particles load of 45%, 50% and 55% v/v of Al2O3. The critical load for the system binder-solid particles, determined by torque rheometry, was 50% v/v of alumina.

Neste trabalho foi projetado o núcleo de um mini motor de passo, com rotor e estator, obtidos a partir do processo de Moldagem de Pós por Injeção (MPI). Foram avaliadas as propriedades magnéticas, elétricas e mecânicas da liga FeNi50 obtida pelo processo MPI. Também por metalurgia do pó convencional obteve-se as mesmas propriedades físicas para comparação, e avaliar os dois processos de fabricação. Na obtenção do mini motor, primeiramente procedeu-se de maneira alternativa com a utilização de ferro puro, bem como, na preparação dos pós de ferro (moagem e misturas), e assim fazendo a avaliação funcionamento do motor. Projetou-se a carga injetável e todos os parâmetros fazendo-se um levantamento por reologia de propriedades como viscosidade e tensão de cisalhamento. Também com DSC/TGA analisou-se os componentes da carga, termicamente, e estipulou-se as temperaturas de extração térmica e química. Após confecção dos corpos de prova levantou-se os dados elétricos e magnéticos. O material que apresentou melhor comportamento para fins de utilização em motores (alta resistividade, alta permeabilidade magnética), foi o injetado de FeNi50 desenvolvido, com resistividade média de 5,06*10-7 Ωm e baixas perdas por histerese magnética. Por fim construiuse o mini motor com FeNi50 a partir de cilindros injetados. O motor foi submetido a testes de acionamento. / This work was designed the core of a mini stepper motor, rotor and stator, obtained from the Powder Injection Molding (PIM) process. Magnetic, electrical and mechanical properties of the alloy obtained by the PIM process FeNi50 were evaluated. Also by conventional powder metallurgy gave the same physical properties for comparing and evaluating the two processes. Obtaining the miniature motor is held first alternative way with the use of pure iron as well as in the preparation of iron powders (grinding and mixtures thereof), thus making the evaluation of engine operation. Designed to charge injection and all the parameters by making a survey by rheological properties such as viscosity and shear stress. Also DSC / TGA was analyzed components of the load, heat, and it was stipulated temperatures of thermal and chemical extraction. After preparation of the specimens rose electric and magnetic data. The material showed the best behavior for the purpose of use in motors (high resistivity, high magnetic permeability), was injected FeNi50 developed, with an average resistivity of 5.06 * 10-7 Ωm and low loss magnetic hysteresis. Finally we constructed the mini motor with FeNi50 from injected cylinders. The engine underwent drive tests.

Neste trabalho, inicialmente, foram obtidos TPSs (amidos termoplásticos) com diferentes concentrações de amido e plastificantes, por processamento em câmara de mistura, com o objetivo de determinar formulações para estudo em extrusora reativa. As formulações de TPS que apresentaram os melhores resultados de torque reométrico foram as que continham 39%m/m de amido. Investigou-se a influência da velocidade da rosca na obtenção de TPS por extrusora reativa, e os resultados mostraram que este parâmetro teve pequena influência na estabilidade do amido termoplástico, sendo possível utilizar 150 rpm de rotação. Foram produzidas 5 blendas com razões de TPS:PEBDL variando de 30:70; 40:60; 50;50; 60:40 e 70:30 para o desenvolvimento de um sistema ligante para a injeção de alumina pelo processo de moldagem de pós (MPI), a partir das quais foi possível analisar a influência do TPS no PEBDL, através de análises de MEV, IF, TGA, DMA e propriedades mecânicas. Quanto maior a concentração de TPS nas blendas, mais heterogênea foi a morfologia observada por MEV e menor o módulo de armazenamento e de perda obtidos por DMA. Este comportamento foi similar ao encontrado pela análise de resistência à tração, que apresentou propriedades mecânicas pobres para elevadas concentrações de TPS. Foram escolhidas três blendas para testar como veículo orgânico em feedstocks de alumina, com carga de partícula sólida de 45%, 50% e 55%v/v de Al2O3. A carga crítica para o sistema ligante-partículas sólidas determinada por reometria de torque foi de 50%v/v de alumina. / In this work, TPSs (thermoplastic starch), with different concentrations of starch and plasticizers for processing in the mixing chamber, were obtained in order to determine formulations for study in a reactive extruder. The TPS formulations that showed the best results for the rheometric torque were those containing 39% w/w starch. The influence of the screw speed to obtain TPS in the reactive extruder was investigated and the results showed that this parameter had little influence on the stability of the thermoplastic starch, allowing the use of 150 rpm rotation speed. Five blends were produced, with TPS:LLDPE ratios of 30:70; 40:60; 50:50; 60:40 and 70:30, to develop a binder for alumina injection by the powder molding process (MPI). From these five systems it was possible to analyze the influence of TPS in LLDPE through SEM analyzes, MFI, TGA, DMA and mechanical properties. The higher the concentration of TPS in blends, more heterogeneous morphology was observed by SEM and the lowest storage and loss modulus were obtained by DMA. This behavior was similar to that found by analysis of tensile strength, which showed poor mechanical properties for high concentrations of TPS. Three blends were chosen for testing as an organic vehicle in alumina feedstocks, with solid particles load of 45%, 50% and 55% v/v of Al2O3. The critical load for the system binder-solid particles, determined by torque rheometry, was 50% v/v of alumina.

Neste trabalho foi projetado o núcleo de um mini motor de passo, com rotor e estator, obtidos a partir do processo de Moldagem de Pós por Injeção (MPI). Foram avaliadas as propriedades magnéticas, elétricas e mecânicas da liga FeNi50 obtida pelo processo MPI. Também por metalurgia do pó convencional obteve-se as mesmas propriedades físicas para comparação, e avaliar os dois processos de fabricação. Na obtenção do mini motor, primeiramente procedeu-se de maneira alternativa com a utilização de ferro puro, bem como, na preparação dos pós de ferro (moagem e misturas), e assim fazendo a avaliação funcionamento do motor. Projetou-se a carga injetável e todos os parâmetros fazendo-se um levantamento por reologia de propriedades como viscosidade e tensão de cisalhamento. Também com DSC/TGA analisou-se os componentes da carga, termicamente, e estipulou-se as temperaturas de extração térmica e química. Após confecção dos corpos de prova levantou-se os dados elétricos e magnéticos. O material que apresentou melhor comportamento para fins de utilização em motores (alta resistividade, alta permeabilidade magnética), foi o injetado de FeNi50 desenvolvido, com resistividade média de 5,06*10-7 Ωm e baixas perdas por histerese magnética. Por fim construiuse o mini motor com FeNi50 a partir de cilindros injetados. O motor foi submetido a testes de acionamento. / This work was designed the core of a mini stepper motor, rotor and stator, obtained from the Powder Injection Molding (PIM) process. Magnetic, electrical and mechanical properties of the alloy obtained by the PIM process FeNi50 were evaluated. Also by conventional powder metallurgy gave the same physical properties for comparing and evaluating the two processes. Obtaining the miniature motor is held first alternative way with the use of pure iron as well as in the preparation of iron powders (grinding and mixtures thereof), thus making the evaluation of engine operation. Designed to charge injection and all the parameters by making a survey by rheological properties such as viscosity and shear stress. Also DSC / TGA was analyzed components of the load, heat, and it was stipulated temperatures of thermal and chemical extraction. After preparation of the specimens rose electric and magnetic data. The material showed the best behavior for the purpose of use in motors (high resistivity, high magnetic permeability), was injected FeNi50 developed, with an average resistivity of 5.06 * 10-7 Ωm and low loss magnetic hysteresis. Finally we constructed the mini motor with FeNi50 from injected cylinders. The engine underwent drive tests.

Neste trabalho, inicialmente, foram obtidos TPSs (amidos termoplásticos) com diferentes concentrações de amido e plastificantes, por processamento em câmara de mistura, com o objetivo de determinar formulações para estudo em extrusora reativa. As formulações de TPS que apresentaram os melhores resultados de torque reométrico foram as que continham 39%m/m de amido. Investigou-se a influência da velocidade da rosca na obtenção de TPS por extrusora reativa, e os resultados mostraram que este parâmetro teve pequena influência na estabilidade do amido termoplástico, sendo possível utilizar 150 rpm de rotação. Foram produzidas 5 blendas com razões de TPS:PEBDL variando de 30:70; 40:60; 50;50; 60:40 e 70:30 para o desenvolvimento de um sistema ligante para a injeção de alumina pelo processo de moldagem de pós (MPI), a partir das quais foi possível analisar a influência do TPS no PEBDL, através de análises de MEV, IF, TGA, DMA e propriedades mecânicas. Quanto maior a concentração de TPS nas blendas, mais heterogênea foi a morfologia observada por MEV e menor o módulo de armazenamento e de perda obtidos por DMA. Este comportamento foi similar ao encontrado pela análise de resistência à tração, que apresentou propriedades mecânicas pobres para elevadas concentrações de TPS. Foram escolhidas três blendas para testar como veículo orgânico em feedstocks de alumina, com carga de partícula sólida de 45%, 50% e 55%v/v de Al2O3. A carga crítica para o sistema ligante-partículas sólidas determinada por reometria de torque foi de 50%v/v de alumina. / In this work, TPSs (thermoplastic starch), with different concentrations of starch and plasticizers for processing in the mixing chamber, were obtained in order to determine formulations for study in a reactive extruder. The TPS formulations that showed the best results for the rheometric torque were those containing 39% w/w starch. The influence of the screw speed to obtain TPS in the reactive extruder was investigated and the results showed that this parameter had little influence on the stability of the thermoplastic starch, allowing the use of 150 rpm rotation speed. Five blends were produced, with TPS:LLDPE ratios of 30:70; 40:60; 50:50; 60:40 and 70:30, to develop a binder for alumina injection by the powder molding process (MPI). From these five systems it was possible to analyze the influence of TPS in LLDPE through SEM analyzes, MFI, TGA, DMA and mechanical properties. The higher the concentration of TPS in blends, more heterogeneous morphology was observed by SEM and the lowest storage and loss modulus were obtained by DMA. This behavior was similar to that found by analysis of tensile strength, which showed poor mechanical properties for high concentrations of TPS. Three blends were chosen for testing as an organic vehicle in alumina feedstocks, with solid particles load of 45%, 50% and 55% v/v of Al2O3. The critical load for the system binder-solid particles, determined by torque rheometry, was 50% v/v of alumina.