Versatility and Reliability Fuel Auto Parts Manufacturers' Needs for Metal Injection
Molding
As successful applications and education expand the knowledge, acceptance
and possibilities of Metal
Injection Molding (MIM), new parts and applications continue to emerge.
In fact, the MIM process has already proven successful for two AFT customers
in the production of high-performance fuel injector valve discs and shift-arm
clevis components for use in automatic transmission actuation.
A common denominator of MIM applications has been in creating a reliable,
production-viable process for medium to high-volume manufacture of components.
In both cases of the fuel injector valve disc and the shift-arm clevis, this
issue has been met by providing economic value, on-time delivery and high quality.
Fuel Injector Valve Disc
In this example of a highly successful MIM application, AFT was called upon
to produce a small (5 mm diameter, 0.5 gram) valve disc produced from 440C
stainless steel heat treated to Rc60. This demanding application would see
1200 million cycles in service. Of the 45 million parts produced to date, zero
rejects have been reported by our customer. This is a true testament to the
viability of high quality, high performance component potential of the MIM
process.
Shift Arm Clevis
In this application, MIM has
proven itself viable in this high-volume production of complex-shaped components.
Larger and relatively heavier components like this produced in volume has a
positive economic impact on raw material cost, which in turn has driven the
competitive edge for MIM products in other market applications.
Tasked with producing a steering column "PRNDL" (Park-Reverse-Neutral-Drive-Low)
shift clevis for use in automatic transmissions, AFT used
the MIM process to produce a relatively large, complex-shaped component which
is heat-treated and the pivot hole reamed to +/- 0.0005". Comprised
of two percent nickel steel, the shift arm clevis, at approximately two inches
long and a weight of 65 grams, is an excellent example of combining more
than two components together to create a quintessential MIM part. In addition
to the economical production of 7,500,000 components produced, this was a
great example of production quality capability coming in at below 25 DPPM
levels.
The MIM Advantage
MIM has clearly become a reliable, production-viable process for the medium
to high volume production of complex-shaped components or low volume applications
where value can be realized. In addition, new materials such as super alloys
and Titanium alloys, sinter bonding of similar/dissimilar materials and the
development of larger and even smaller parts is on the horizon for the future
of MIM technology.
Continued development of published industrial material standards, end-user
based education, research and development, automation and increased recognition
of successful applications will continue to drive Metal Injection Molding's
impressive growth.
Have questions about MIM Technology and how it can impact your project? Contact
Andrew Hanson, Vice President at andyh@pcc-aft.com or
call 303.833.6000.
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