Graduate Thesis Or Dissertation
 

The effect of feedstock composition on defect evolution in powder injection molded ceramic microarrays using simulations and experiments

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https://ir.library.oregonstate.edu/concern/graduate_thesis_or_dissertations/xs55mg03j

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  • Micro Powder injection molding (μPIM) is a cost-effective technique for producing small, complex, precision parts in high volumes from ceramic and metal nanoparticles. This study focuses on research conducted on fabrication of Micro Ceramic Arrays (MCAs) parts using μPIM. MCAs are widely used as the major components and design features for many microsystems in various applications, such as micro fluidics, micro optics, micro heat exchangers, micro transducers, micro reactors, medical instruments and devices, IC packaging, etc. However, lots of defects are associated while molding these MCAs with micro features. These defects can be avoided by carefully studying the part geometry, feedstock properties and studying the effect of change in processing parameters on the fill of micro features. In this study we dealt with all the three methods to avoid defects with a concentration on effect of feedstock properties on defect occurrence. In order to have a good understanding of the μPIM process and to provide the necessary data for simulation studies, characterization of the feedstock is essential. In this thesis, characterization of feedstock consisting of alumina nanopowder (average particle size of 400 nm) with ethylenepropylene/ wax (Standard Mix) and polyacetal binder systems (Catamold AO-F, BASF) for μPIM is reported. It is found that the Standard Mix system has lower viscosity and heat capacity compared to the Catamold AO-F. However, it can be inferred from the results that Catamold AO-F fills the microcavities (50μm) in a more efficient way, despite having a higher viscosity at higher shear rates. These results from Moldflow Simulations were further varied using experimental platforms and scanning electron microscopy.
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