When designing parts for sintering, there are several key guidelines to follow to ensure success and high-quality results.
8 Essential Guidelines for Sintering Design
1. Avoid Cylindrical Shapes Perpendicular to the Compacting Direction
Cylindrical shapes in this orientation can lead to uneven compaction and result in poor sintering quality.
2. Avoid Acute Tooling Transitions and Frontal Shapes with Thin End Sections
These shapes can cause stress concentration during sintering, leading to cracking or deformation of the final part.
3. Avoid Punches with Thin Wall Thickness and Deep and Narrow Notches
Thin-walled punches can lead to insufficient pressure during compaction, resulting in incomplete sintering. Deep and narrow notches can create stress concentration points and affect the structural integrity of the part.
4. Consider the Configuration of the Sintering Furnace
For optimal gas flow and cost-effectiveness, a square cross-section is recommended. However, the dimensions of the furnace can be flexible depending on the specific requirements of the materials being processed. For high-temperature sintering above 2000°C, a suspended cylindrical resistor supported by current feed-throughs may be necessary.
5. Consider Gas-Flow Distribution
There are three broad options for gas-flow distribution in sintering furnaces - with a box, without a box, or no distribution at all. The choice depends on the specific requirements of the sintering process.
6. Fit Sintering Parameters to the Part Material and Size
The sintering cycle should include intermediate dwellings and different heating rates to ensure temperature homogeneity while minimizing cycle time. This is particularly important for parts produced using the binder jetting technology, as they can have a higher tendency to lose shape during sintering.
7. Consider Potential Issues During Sintering
Issues such as warping, sagging, and defects can occur during sintering. Design considerations, such as adding spacers, support ribs, or special setters, can help minimize these issues and ensure the production of high-quality parts.
8. Select the Appropriate Sintering Furnace
The selection of a sintering furnace depends on various factors, including furnace size opening, operating temperature, furnace process atmosphere, material type and mass of the component, and required furnace output. Low-volume production may require a batch furnace, while medium- to high-volume production may require a continuous furnace or custom furnace.
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