C Quality Managment in The PIM Process

powdercon Material Engineering
Quality Management and Quality Control in the Powder Injection Moulding Process Dr.-Ing. Henri Cohrt Ing.
Dr.-Ing. Henri Cohrt Marschallstrasse 2a D-35444 Biebertal Germany Tel.: +49 151 2290 1386 Fax: +49 6409 804970 Henri.Cohrt@powdercon.de
The powder injection moulding process is widely used to produce high precision structural parts of very high complexity in shape. The variety of materials ranges from ceramics and hard metals to stainless steels and low alloyed steels. As a near net shape process the entire process is very complex and needs the full attention of all the people incorporated. The early design activities are influencing the quality of the final product as well as the tool design and fabrication, the selection of raw material and binder system, and all single production steps and the secondary operations. For that, a well designed quality management and control system is necessary to control the powder injection moulding process in all the details. Such a system should incorporate a carefully organized systematic Failure Mode and Effect Analysis (FMEA). The combination of a high performance process monitoring system with the extensive application of statistical procedures creates the basis for a Statistical Process Control (SPC) system that meets all the requirements to produce multi-functional structural parts of high complexity in shape and of high performance materials. The paper will discuss such a quality management and control system in detail.
Dr.-Ing. Henri Cohrt Ing.
Abstract
1. Introduction 2. What is possible
3. Principle problems 4. How to realize improvements with respect to technical characteristics and economy? 5. Design of a Quality Management system 6. Closing remarks
Content
Metal / Powder Injection Molding is the combination of design features of plastic injection molded parts with the properties of high performance metals, hard metals or ceramics in a (near)-net-shape process
Source: Schunk Sintermetalltechnik GmbH
Characteristics of the Process
Content
Clamping device for a breaking system ( 3 MIM parts)
Functions Guiding Adjusting Clamping Connecting
Functional Integration
Connector Reduction of process steps
Production of a forged and drilled bronze head Production of a steel tube Production of a spike Elimination of a bracing operation
Reduction of production steps

Static Mixer Elimination of electro-erosion machining
Simplification of Production
Actuator Combination of complex shape and high strength steel
Realization of new Design Features

Mini gears for a tooth brush Production quantity of 1,5 Mil. gears per year
Large Scale Production

Decorative chromium coated protection cap for a car looking system
Wide Range of Secondary Operations Available

Lever for a sun roof Substitute for Precision Casting
Substitution of Existing Processes for Economic Reasons

Carbonyl Iron Powder
10 m
25 m
Pure Iron Carbon Steel with 0,6 % C
Micro-Structure Engineering Development of Pure Iron Carbon Steel
Carbonyl Iron Powder
Chromium Carbide Powder

10 m
12,5 m
2,5 m
100 Cr 6 Bearing Steel As Sintered
Micro-Structure Engineering Development of 100 Cr 6 Bearing Steel
Inert Gas Atomized Stellite 6 Powder
7,5 m
5 m
Stellite 6 wear resistant steel
Micro-Structure Engineering Development of Stellite 6 Wear Resistant Steel
Hardened
Stress [MPa]
Total Stain [%]
Effect of Heat Treatment on Fe 2.5%Ni 0,6%C Steel
Complexity of Geometry
High
Medium
Forging, Die Casting PM (Die Pressing)
Metal / Powder Injection Molding (MIM / PIM)
Precision Casting
Low
Machining
Low Medium High
Complexity of Geometry
Competition of Processes
Content
Metal Hard MetalCeramic-
Powder
~ 60 vol-%
Mixing Homogenizing and Granulating
Organic Binder
~ 40 vol-%
Shaping using Injection Molding
Removal of Binder
Sintering
Secondary Operations
Complex Structural Parts Ready to Use
Process Schematic
Shell-like arranged porosity due to sheer-induced separation processes in the feedstock during mold filling
Typical Defects
As molded (green condition)
De-bound (brown condition)
Shrinkage hole due to sheer-induced separation processes in the feedstock during mold filling
(Visualization by means of micro-focus X-raying)
Typical Defects
Material Specification: AISI 316L
Plastic Elongation [%]
Code of Supplier
Round Robin Tests (Working Group MIM, Germany 1997)
3. Principle Defects 4. How to realize improvements with respect to technical characteristics and economy? 5. Design of a Quality Management system 6. Closing remarks
Content
Visualization of Process Optimization by means of Statistical Process Control Procedures

Dimension 9,94 0,06 mm
Test 1 Co2 - Extraction Vacuum Sintering Test 2 N2 - Partial Pressure Vacuum Sintering 1 Test 3 N2 Partial Pressure Vacuum Sintering 2 Test 4 a Co2 - Extraction High Temperature Belt Furness
Specimen No.
Test 4 b Co2 - Extraction High Temperature Belt Furness Test 4 c Co2 - Extraction High Temperature Belt Furness Test 5
Co2 Extraction, N2-Partial Pressure Partial
Walking Beam Furness Test 6

Air , N2-Partial Pressure Partial
Comparison of Different De-binding and Sintering Conditions

Walking Beam Furness
Content
Quality Control
Quality Management
Quality control means:
To find errors. To avoid errors!
Quality management means:
From the economic point of view avoiding errors has the priority
What is the Focus of Quality Management?

Cost
Process Design, Row Material and Equipment Selection
Production Process
Final Inspections
Shipment to the Customer
Progress of the Process
Assembly and Installation
Cost of Quality Control and Lack of Quality

Cost of QM & QC
Warranty Time and After
Defect Quote
Project Definition
Design & Development
Production Planning
Quality Control
Product in Operation
Defect Detection Defect Generation and Setting of its Pre-Conditions
Generation of 75 % of Defects
Detection of 80 % of Defects
Course of Life Cycle
Schedule of Defect Generation and Defect Detection

Source: Deutsche Gesellschaft fr Qualitt
You need a strategy for your system! Organization + Documentation Manufacturing + Control Resources Dr.-Ing. Henri Cohrt Ing. Personnel + Training
A Quality Management system should be regarded as a tool for a never ending improvement of the Metal / Powder Injection Molding Process
How to realize a Quality Management System
Strategy
Analysis
Customer Satisfaction
Guidance
Control
The Nature of a Quality Management System
Definition of Quality
Description of the Product and the Process
Quality Management Handbook Process Instructions
Process Analysis FMEA, 6 Sigma Prototype Production
Working Instructions Inspection of the Quality Management System by means of Internal Audits External Accredited Certification Authority e.g. in accordance to EN ISO 9001 - 2000 Customers
Revised Product and Process Description
Results from Quality Control Activities Start Production
Development of a Quality Management System for the MIM/PIM Process
Potential consequence
Potential Defect
Potential Cause of the Defect
Preventive Action
Testing Procedures
In-correct dimension
Wrong feedstock Defective composition scale Wrong sintering Furnace setting
Preventive calibration Training of operator
Density measurement of feedstock Comparison of furnace setting with process documentation Checklist (working instruction)
84
In-correct dimension
Weighting Factors
Risk Priority Number RPZ = B x A x E
FMEA-Form according to Deutsche Gesellschaft fr Qualitt
B Impact, that means the effect on the customer 1 2 to 3 4 to 6 7 to 8 9 to 10 hardly observable inconsiderable or less disturbance low disturbance high impact, e.g. stop of production very high impact, e.g. risk for human beings
A - Probability of occurrence of a defect 1 2 to 3 4 to 6 7 to 8 9 to 10 unlikely, very low low medium high
E Probability of detection before shipment to the customer 1 2 to 5 6 to 8 9 10 high medium low very low unlikely
Weighting Factors
The Risk Priority Number is calculated by multiplying the Weighting Factors RPZ = B x A x E
From the RPZ the priorities of actions are given by the following schema: Dr.-Ing. Henri Cohrt Ing.
Low priority
Medium Priority
High priority
Very high priority
125
500 Risk Priority Number
1000
The interpretation of the Risk Priority Number
Internal Spezification
60 50
Upper Specification (Mean plus 3) Upper Control Limit (Mean plus 2) Mean
Maesurement
40 30 20 10 0
External Specification
(tolerance band according to technical drawing)
Lower Control Limit (Mean minus 2) Lower Specification (Mean minus 3)

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115
Sample No.
Design of a Quality Control Card
Archer 3 Archer 3 Archer 2 Archer 1
Improvement of Process Capability by means of Statistical Process Control (SPC)
Human Beings
Education
Material
Surface Dimensions Scattering Mechanical Properties
Private Problems Job-Related
Dust Humidity Temperature Process
Environment
Tooling Cleaning Maintenance
Organization
Workflow
Methods Machine
Quality-Affecting Influences
Development and Test Production
Short Term Evaluation of Machine / Process Capability
Approval for Serial Production Focus on Long Term Validation of Machine / Process Capability Human Beings Machine Material Methods Environment To be Subjected to a Process of Permanent Improvement
Serial Production
Machine Capability
Process oriented, but, min. 50 measurements Result: Cm and Cmk
Process Capability
Adequate long period of time under normal conditions of serial production to secure that all quality affecting circumstances can become effective. Recommendation: min 125 single parts in 3 to 5 control samples better is 20 Production days Result: Cp and Cpk
Process Evaluation and Validation
Working Instructions Handling Storing Conditions
Pure Powder Pre-Alloyed Powder Powder Composition
Binder or Components of Binder
Recycled Feedstock (Gating Material)
Properties Production Data
Metering Out
Working Instructions
Mixing and Homogenization
Granulation
Feedstock Characterization
Properties Production Data
Documentation related to Feedstock Preparation
Content
The Basics of the MIM / PIM process are well understood
There are many different process routes available with respect to raw material selection binder selection and binder composition feedstock production de-binding processes sintering processes In the mean time a lot of measurement technologies have been developed to control the raw materials and feedstock characteristics in principle also the basics of the two-phase-flow-mechanics are available the electronically controlled injection molding machines allow highly sophisticated control of the molding process there are also highly sophisticated furnace systems available to control the de-binding and sintering processes But nevertheless, very small scattering in the very complex system of a huge number of independent parameters have in special situations dramatic effects on the result of the entire MIM / PIM process and are causing big problems with respect to the quality of the product.
Closing Remarks
the MIM / PIM process as an entire process is still very young and has its secretes the interdependences between the single, at the first glance independent process parameter are not very clear and cannot be descript precisely enough to make MIM / PIM a fully automated process. MIM / PIM still needs highly experienced operators to make the process successful. A well designed Statistical Process Control system combined with an excellent Quality Management system is necessary to produce
multi-functional, complex shaped structural parts of high performance materials in high quantities in an economic way utilizing the Metal / Powder Injection Molding Process
Consequences
CO2 De-binding Final de-binding and sintering in one Furnace
Process Number
1.175
Pre-de-binding in air
Final de-binding and sintering in one Furnace
1.250
Pre-de-binding in air
Final de-binding on N2
Sintering in Vacuum 1.550
Process Time [h]
Economic Comparison of Different Processes - ideal Conditions and comparable Capacities (especially quality issues are not regarded)

C Quality Managment in The PIM Process

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powdercon Material Engineering

powdercon Material Engineering

Dr.-Ing. Henri Cohrt Ing.

powdercon Material Engineering

1. Introduction 2. What is possible

Dr.-Ing. Henri Cohrt Ing.

powdercon Material Engineering

Dr.-Ing. Henri Cohrt Ing.

Source: Schunk Sintermetalltechnik GmbH

Characteristics of the Process

powdercon Material Engineering

1. Introduction 2. What is possible

Dr.-Ing. Henri Cohrt Ing.

powdercon Material Engineering

Clamping device for a breaking system ( 3 MIM parts)

Dr.-Ing. Henri Cohrt Ing.

Functions Guiding Adjusting Clamping Connecting

powdercon Material Engineering

Connector Reduction of process steps

Dr.-Ing. Henri Cohrt Ing.

Reduction of production steps

powdercon Material Engineering

Dr.-Ing. Henri Cohrt Ing.

Static Mixer Elimination of electro-erosion machining

powdercon Material Engineering

Dr.-Ing. Henri Cohrt Ing.

Actuator Combination of complex shape and high strength steel

Realization of new Design Features

powdercon Material Engineering

Dr.-Ing. Henri Cohrt Ing.

Large Scale Production

powdercon Material Engineering

Dr.-Ing. Henri Cohrt Ing.

Decorative chromium coated protection cap for a car looking system

Wide Range of Secondary Operations Available

powdercon Material Engineering

Dr.-Ing. Henri Cohrt Ing.

Lever for a sun roof Substitute for Precision Casting

Substitution of Existing Processes for Economic Reasons

powdercon Material Engineering

Carbonyl Iron Powder

Dr.-Ing. Henri Cohrt Ing.

Pure Iron Carbon Steel with 0,6 % C

Micro-Structure Engineering Development of Pure Iron Carbon Steel

Carbonyl Iron Powder

Chromium Carbide Powder

powdercon Material Engineering

Dr.-Ing. Henri Cohrt Ing.

100 Cr 6 Bearing Steel As Sintered

Micro-Structure Engineering Development of 100 Cr 6 Bearing Steel

powdercon Material Engineering

Inert Gas Atomized Stellite 6 Powder

Dr.-Ing. Henri Cohrt Ing.

Stellite 6 wear resistant steel

Micro-Structure Engineering Development of Stellite 6 Wear Resistant Steel

powdercon Material Engineering

Dr.-Ing. Henri Cohrt Ing.

Total Stain [%]

Effect of Heat Treatment on Fe 2.5%Ni 0,6%C Steel

powdercon Material Engineering

Dr.-Ing. Henri Cohrt Ing.

Forging, Die Casting PM (Die Pressing)