Metal Injection Molding Auto Parts

Compared with traditional machining methods, MIM technology has the characteristics of high precision, high strength, high shape complexity, material diversity, and low cost, so Metal Injection Molding Auto Parts has been widely used in automobiles. Metal Injection Molding Turbocharger Rotor, Metal Injection Molding Turbocharger Impeller, Metal Injection Molding Turbocharger, Metal Injection Molding Rearview Mirror Holder, etc. The Powder Metallurgy Division of Qinhuangdao Zhongwei Precision Machinery Co., Ltd. was established in In 2007, located in Qinhuangdao City, Hebei Province, there are two production lines of metal injection molding MIM process and powder metallurgy PM. The company has independent research and development products: German Maya warp knitting machine sensor chain block, electric actuator gear, automobile oil pump rotor , washing machine transmission gear and other products, the powder metallurgy products produced cover automobiles, motorcycles, power tools, home appliances, textile machinery parts and other fields. Our company is a comprehensive high-tech enterprise integrating R&D, production and sales of copper alloy, iron base, stainless steel base, aluminum alloy, nickel alloy, cobalt alloy, tungsten alloy, cemented carbide and powder metallurgy structural parts.

Product Description

1. Implementation standards: the company strictly implements ISO9001, ISO14001, IATF16949 certification

The products have passed the certification of ROHS, FDA EU, etc.

2. Product material standards: ISO, GB, ASTM, SAE, EN, DIN, BS, AMS, JIS, ASME, DMS, TOCT, GB

3. Main processes: metal injection molding MIM, powder metallurgy PM, investment casting, die-casting aluminum,

4. Available materials for powder metallurgy:

Copper alloy, iron base, titanium alloy, stainless steel base, aluminum alloy, nickel alloy, cobalt alloy, tungsten alloy, cemented carbide, hydroxy alloy, soft magnetic material and 3D printing can be customized according to customer requirements.

Product Category

Compared with traditional processing methods, MIM technology has the characteristics of high precision, high strength, high shape complexity, diversified materials, and low cost, so MIM technology has been widely used in automobiles. The MIM parts currently used in automobiles are generally iron-based materials, mainly Fe-Ni alloy steel, Fe-0.4C-1Cr-0.75Mn-0.2Mo alloy steel, pre-alloyed Cr-Mo-C steel, Ni -Cr-Mo-C steel, 316L, 17-4PH, 400 series, HK series stainless steel, Inconel713C nickel-based heat-resistant superalloy steel.

1. Turbocharger

The turbocharger is mainly composed of a turbine, a pump wheel, a rotor, an impeller, etc. It uses the inertial force generated by the high-pressure exhaust gas discharged from the engine to drive the pump wheel to rotate, and the rotor drives the turbine to rotate to increase the engine intake pressure. In recent years, the research and development and production of turbocharger MIM parts have become the focus of scientific research, and turbochargers are also one of the iconic parts of MIM manufacturing. Its structure is extremely complex, the working environment is harsh, and the precision is high. However, other processing methods have high cost and difficult to control precision. Turbocharger parts are mainly composed of nickel-based ultra-high temperature alloys, titanium alloys and other materials, which were previously processed by traditional powder metallurgy technology.

BASF in Germany has made a great contribution to MIM turbocharger parts, BASF uses a unique Catamold process to manufacture MIM turbocharger parts. The mechanical strengths of MIM parts and precision cast samples were compared at room temperature, demonstrating the excellent material properties that can be achieved with the Catamold process.

In China, Beijing University of Science and Technology Co., Ltd., which has been cooperating with Zhongwei Precision Co., Ltd., used argon atomized K418 alloy powder as raw material, added self-designed multi-component paraffin-based binder, and used injection molding technology to prepare a complex-shaped turbocharger. The subsequent hot isostatic pressing and heat treatment process are optimized to prepare a supercharger turbine with dense, uniform structure, excellent mechanical properties, conforming to the use requirements, and good surface finish. It has broken through the key technical difficulties such as the structural design of the supercharger turbine with complex shape, the optimization of injection molding process parameters, the sintering densification and the control of dimensional accuracy, and the comprehensive mechanical properties are significantly improved compared with the casting turbine.

2. Fuel injector

Many small precision composite parts in automobiles can be manufactured by MIM process. Manufacture of composite parts is generally through forging, precision casting and other methods. When manufactured using the MIM process, it can improve production efficiency, improve accuracy, save materials, reduce processes, and reduce costs. The electronically controlled gasoline injector on the automobile engine is composed of more than 20 parts, of which the iron core, armature, magnetic guide plate, guide body and other parts constitute the magnetic circuit structure of the injector. These Metal Injection Molding Auto Parts are composed of Made of soft magnetic alloy material.

Compared with the traditional gasoline injector, the overall performance of the fuel injector manufactured by MIM technology is improved.

India-US MIM Technology Co., Ltd. used MIM to develop and manufacture 4 components of gasoline direct injection pump, the component material is 440C stainless steel, the density ρ>7.65 g/cm3, σbmax is 480MPa, σs is 150MPa, δ is 45%, Rockwell The maximum hardness is 100 HRB, which not only reduces the manufacturing cost by nearly 35%, but also improves the performance of the pump and saves the fuel by nearly 10%-20%.

440C stainless steel MIM seal mounts for direct-fed injector assemblies. This is a complex structural part with multi-angled grooves and top holes. The sealing support made of MIM has a near-net structural shape, ρ is 7.54-7.65 g/cm3, σb is 1600MPa, σs is 1400MPa . The MIM process saves nearly 30%-40% in cost compared to other production processes . At the same time, the cooling piston nozzles used on V-8 cylinder engines are also made with MIM .

3. Sensor

With the advancement of science and technology, the types and functions of sensors used in automobiles tend to be diversified, intelligent and miniaturized. Depending on the application area, sensor housings are used in systems such as engine, chassis, body, and navigation.

Many sensors on the engine, chassis, body, navigation and other systems have been manufactured using the MIM process, such as pressure sensor assemblies, airbag sensor inserts, oxygen sensors, steering sensors, cruise control sensor bases, sensor housings, etc.

Sensing element, threaded port, support ring, sensor kit developed by US-India Injection Molding Technology Private Limited using MIM process to measure the pressure of the inlet pressure of the pass-through fuel mixture per cylinder of passenger car engines Sensor, these parts are made of 17-4PH stainless steel. After heat treatment, σs is 1103MPa, σbmax is 1228MPa, δ is 7%, and parts with hardness between 35-40 HRC are formed close to the final shape.

Airbag is a measure to protect the life of the driver when the car encounters an accident. It can be divided into mechanical type and electronic type.

The mechanical type is triggered by the inertia ball impacting the firing pin, and the electronic type is triggered by the sensitive element. The airbag is composed of D-shaped shaft, embedded tab and ignition pin, all of which are made of MIM17-4PH stainless steel. After heat treatment, σb is 1170MPa, σs is 1100MPa, hardness is between 38-41HRC, δ is 7.0%, density Between 7.60-7.68g/cm3. The dimensional accuracy, stiffness, strength and wear resistance of the parts all meet the requirements of use. Compared with the precision casting process, the MIM process has the advantages of good surface roughness, high tensile strength, realizing the combination of parts, reducing the number of parts, reducing costs, and improving efficiency.

In addition to the above parts, the ignition key, engine rocker arm parts, steering gear U-clip, reverse gear synchronizer, valve lifter, piston ring, combustion chamber cover, car retainer, etc. on the car are all manufactured by MIM process.

4. The application prospect of MIM technology in automobiles

With the advancement of science and technology, the main direction of automobile development is energy saving, environmental protection, comfort, intelligence and light weight. The application prospect of MIM automobile products in automobiles is huge.

Using MIM technology, tiny automotive parts can be designed as a whole or multiple components, and the MIM process is used for one-time injection molding, so that the parts can achieve the characteristics of miniaturization, integration, and low cost under the premise of satisfying performance. At the same time, it can manufacture parts with complex shapes such as external grooves, external threads, cross holes, blind holes, rib plates, grooves and key pins.

For example, India-US Metal Injection Molding Technology Co., Ltd. uses MIM to manufacture spur gears that control the failure of automobile rear doors. Kunshan MagnaClosures is using this new product. Now India-US MIM Co., Ltd. supplies the market every year. 720,000 such parts, 30% less cost than using powder metallurgy . At the same time, the company uses MIM technology to develop and produce a fuel control device sector gear, which provides nearly 3 million such parts to Bosch every year.

The application of MIM technology has played an immeasurable role in the lightweight, energy saving, functional integration, and cost reduction of auto parts. The application market prospect of MIM technology in automobiles is very broad.

Post Casting Process

1. Heat treatment: annealing, carbonization, tempering, quenching, normalizing, surface tempering

2. Processing equipment: CNC, WEDM, lathe, milling machine, drilling machine, grinder, etc.;

3. Surface treatment: powder spraying, chrome plating, painting, sandblasting, nickel plating, galvanizing, blackening, polishing, bluing, etc.

Moulds and Inspection Fixtures

1. Mold service life: usually semi-permanent. (except for lost foam)

2. Mold delivery time: 10-25 days, (according to product structure and product size).

3. Tooling and mold maintenance: Zhongwei is responsible for precision parts.

Quality Control

1. Quality control: the defective rate is less than 0.1%.

2. Samples and trial run will be 100% inspected during production and before shipment, sample inspection for mass production according to ISDO standards or customer requirements

3. Testing equipment: flaw detection, spectrum analyzer, golden image analyzer, three-coordinate measuring machine, hardness testing equipment, tensile testing machine.