Process/design optimization for powder injection molding of turbocharger vane by rheological & computational analysis

Abstract

Powder injection molding, which is a powder-based net-shape technology, has enabled the development of a mass production process for super alloy turbocharger vanes. Here, the conditions of the nickel-based superalloy feedstock were characterized and simulated to predict possible defects and to determine the optimal process conditions. The test results show that the feedstock shows shear thinning behavior at temperatures of 170 °C, 190 °C, and 210 °C, whereas shear viscosity shows the lowest value at its highest temperature. A shear rate region could be found in the gate or thin vane regions, and this could form a bond without suitable a shape or injection speed. This research focuses on improving the quality of superalloy powder injection-molded parts, by providing information on possible defects that could occur prior to processing. © 2020