Innovative dynamic controls of mold temperature during ceramic injection molding for a better control of filling behavior
FERRARO C. 1, RÜEGER T. 3, BEURET K. 2, HASANOVIC S. 1, BÜRGISSER B. 3
1 Ceramaret SA, Milvignes, Switzerland; 2 Primaform AG Werkzeug und Formenbau, Thun, Switzerland; 3 iRAP, Institute for Applied Plastics Research, HEIA-FR (HES-SO), Fribourg, Switzerland
Ceramic injection molding (CIM) is one of the best known and most widely used ceramic manufacturing processes. CIM is often chosen when complex geometries, tight tolerances and high production volumes are required. Ceramic powders are mixed with various binders and then injected into a mold under high pressure and temperature. To properly fill the cavity, the starting material is melted at a high temperature (depending on the Tg of the binder system) and then injected into a mold cavity that is normally maintained at a much lower temperature. Such temperature gradient can significantly affect the quality of the injection molded part. The Holt melt front, which comes into contact with the cold mold surfaces during the filling phase, tends to cool very rapidly, especially in the case of highly filled feedstocks. Such process can greatly affect the filling behavior and the state of matter in the different areas of the part, leading potentially to variations in density, internal stresses and defects. One of the many disadvantages of CIM is that such defects are often not visible until the entire manufacturing cycle, including the thermal treatment (debinding and sintering), is completed. Due to the large volume fraction of polymeric binders, these steps can usually take several days, if not weeks. As part of the current project, Ceramaret, Primaform and iRAP have been investigating the use of a variothermal control system during the injection of ceramic parts. The hot water-based variothermal system allows the mold cavity to be heated to a higher temperature than the standard process. Maintaining a higher temperature in the mold can provide several benefits, improving the material flow and in general the filling behavior of the feedstock. In addition to the variotherm, a conformal cooling system was also investigated in order to further improve the quality of the injected parts. The conformal cooling is a set of channels which follows the profile of the mold cavity allowing therefore a more uniform cooling phase. A more uniform cooling allows ideally to reduce the internal tensions and therefore potential post deformation generate by a differential cooling of the molded part. In this study a simple test geometry with variable wall thicknesses was taken into consideration in order to compare the filling behavior with a standard CIM versus a CIM coupled with a variotherm system and a conformal cooling. Preliminary results on the effect of variotherm with different injection conditions on the injectability of test bars and extremely thin geometries are presented, showing the significant improvements achieved.