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Magnetic Materials - The Attraction of MIM!
When a manufacturer of guided missiles needed some small complex components with particularly good magnetic properties, they turned to Metal Injection Mouldings Ltd to provide the solution.
The “MIM” process uses an extremely fine powdered metal, which is coated with binder, then formed into the required shape using similar techniques to plastic injection mouldings. The binder is subsequently removed and the pure metal part is fired at high temperature, resulting in a component with 95 to 98% density.
The high density achieved, results in excellent magnetic properties for Pure Iron, 50%Ni/50%Fe, or Iron/Silicon materials. MIM parts in these alloys have also been used for Aircraft Actuators, Dot-Matrix Printer Heads, Seat-Belt electronic controls, Water & Blood Measuring devices and other equipment requiring small parts with specific magnetic responses.
The high density of metal injection mouldings also results in good mechanical strengths for alloy steels, stainless and tool steels or Nickel/Cobalt alloys.
Metal Injection Mouldings are ideal for small components with complex shapes or intricate detail, such as blind holes, square holes, threads, fine teeth and lettering, which can all be economically formed.
The “MIM” process uses the same design philosophies as plastic injection moulding, but with the superior strengths of steels – a great attraction to designers and engineers!
Metal Injection Mouldings for Surgical Equipment
The photograph in shows some MIM components for female sterilisation equipment. This instrument was to be a disposable product, so costs needed to be kept to the minimum. As the parts would not be easy to machine from solid, a manufacturing method had to be found that was consistent, efficient and economic. The designers turned to Metal Injection Mouldings Ltd, who produced the parts in 316 Stainless Steel, with a vibratory polished finish.
The Metal Injection Mouldings included all the detail and were made to tolerances that did not require additional machining operations. This resulted in clean looking parts, efficiently produced at economical costs.
The Smallest Parts on the Largest Aircraft
Metal Injection Mouldings Ltd have recently produced some of the smallest parts used in the giant Airbus A380 airliner.
The photograph shows a Microswitch Arm made by the "MIM" process. A pair of these MIM components replace 22 existing parts on a de-icing valve, previously made for the A320 aircraft.
The original Microswitch units were assembled from 11 items, including pressings, small shafts, nuts, washers etc., compared to the one-piece MIM parts. Furthermore, the 2 pillars incorporate recessed rivet features, enabling the very quick fitting of a plastic micro-switch.The use of MIM parts considerably reduced the cost of purchasing, stocking, controlling and assembling these units.
The MIM parts are made in 316 stainless steel and are the first MIM parts to be used in the Airbus family.
FORTHCOMING EXHIBITIONS:-
DSEi 2009 8th-11th September 2009.
ExCel, London. See us on Stand 851.
Metal Injection Mouldings Ltd - Registered in England & Wales No 03118895; VAT No GB 806 6549 14
Registered Office - Davenport Lane, Altrincham, Cheshire WA14 5DS