Helmholtz-Zentrum Geesthacht, Monday, 21-May-2012 17:50:26 CEST
http://www.hzg.de/institute/materials_research/structure/magic/powder_technology/profile/index.html.en

Profile

Staffmembers of the department powdertechnology in from there combined sinter- and debinding furnace XVAC Staffmembers of the department powdertechnology in from there combined sinter- and debinding furnace XVAC

The Powder Technology department’s objective is to manufacture highly complex components from fine metallic powders, optimised for specific applications. With regard to component manufacture, the department thus provides a consistent technological complement to powder production by means of gas atomisation or high-energy ball milling, which is also based at the Institute of Materials Research. The process is based on injection moulding using metallic powders (MIM: Metal Injection Moulding), which combines the suitability of injection moulding (similar to plastics forming applications) for producing a wide range of forms, with consolidation of the powder by means of sintering.

The focus of our work is to further develop MIM technology, in order to enable application of these materials, which have to date been difficult or impossible to process. We further intend to expand MIM technology’s potential areas of application beyond pure component manufacturing. Partial processes (such as injection moulding, debindering and sintering) thus make it possible to use a variety of different methods, for example, to bond identical or different materials, joints, porous structures etc.

To realize our objectives, we are not only engaged purely in process development but also in material and feedstock development, depending on the specific project. The feedstock production takes place entirely in a controlled atmosphere, so that even oxygen-sensitive powders can be processed. Current development work of particular note includes the MIM processing of magnesium and of TiAl-based powders. Both of these topics are incorporated in the Helmholtz program "Advanced Engineering Materials". The special challenge posed by Mg-based and Ti-based alloys is due to these materials’ high affinity for oxygen. Even minimal quantities of oxygen that might make their way into the process have a strong effect on the mechanical properties of the materials and can leave the sintered components useless. The fine powders used in the MIM process present a particularly large surface area and must therefore be protected by using process engineering measures and, if necessary, measures that make use of the materials’ physical properties.

Implantable screws for treating the spine, MIM made of TiAl6Nb7 powder (Design: Tricumed Medizintechnik GmbH) Implantable screws for treating the spine, MIM made of TiAl6Nb7 powder (Design: Tricumed Medizintechnik GmbH)

One example of a successful transfer of development results to the realm of commercial applications is provided by the long-established cooperation with the Kiel-based company Tricumed Medizintechnik GmbH. A jointly funded project led to the development of a special MIM process route for the processing of the titanium alloys TiAl6Nb7 and TiAl6V4 into highly ductile components that are nearly as strong as the alloys in their initial state. In late 2003, the partners’ efforts led to the founding of the company TiJet Medizintechnik GmbH as a subsidiary of Tricumed, which today is the world’s first commercial manufacturer to offer MIM production of implants made of titanium.