Metal Injection Molding in the aerospace industry

Technical innovations and advanced materials add to Metal Injection Molding’s appeal

Following the early successes for Metal Injection Molding in the late 1970s (see below), the technology has found a number of applications in the aerospace sector, including high performance engine components, seatbelt parts, latches and fittings, spray nozzles and vane adjustment levers, to name just a few.

Whilst the majority of current MIM aerospace applications will inevitably remain confidential, Pratt & Whitney announced in 2015 that its PurePower® PW1500G engines include Metal Injection Moulded components, as well as being the first to feature entry-into-service jet engine parts produced using Additive Manufacturing.

There has in recent years been a renewed interest from the aerospace sector in using Metal Injection Molding to manufacture superalloy components for use in critical aero engine applications.

Primary MIM materials for aerospace applications include stainless steels (316L, 410, 420, 17-4 PH, 13-8 PH), superalloys (Hastelloy X, Inconels 625, 713C and 718, Nimonic 90, and Udimet 700) and variants.

Titanium alloys TiAl and Ti-6Al-4V are also used and MIM’s ability to produce complex, high volume, high performance titanium components offers attractive possibilities to reduce aircraft weight.

THE WORLD OF MIM, CIM and SINTER-BASED AM TO YOUR INBOX
Subscribe to our weekly newsletter
Sign up

Aerospace seatbelt component

Metal Injection Molding in the aerospace industry
MIM low alloy steel seat belt component manufactured by MimEcrisa SA, Spain

A high-strength Metal Injection Moulded seatbelt component for the aerospace sector is shown. This 90 g complex shaped part is produced from an Fe7Ni0.6C steel alloy which, after heat treatment, provides a tensile strength greater than 1200 MPa.

Typically, a part of this size (80 mm diameter) and weight would be outside the conventional size range for MIM parts. Thanks to the part’s complexity, however, Metal Injection Moulding was able to provide the most cost-effective solution.

From the history books: airliner flap screw

Metal Injection Molding in the aerospace industry
This airliner flap screw seal, from 1979, was an early success for Metal Injection Moulding (Courtesy Parmatech Inc, and MPIF)

MIM’s earliest successes were in the aerospace sector. Dating from 1979, this 50.8 mm diameter ring shaped part was used in the flap mechanisms of Boeing 707 and 727 airliners, as well as the German VFW 614 transport aircraft.

In addition to corrosion resistance, the part was reported to have outstanding properties as a result of its high density, which was over 96% of theoretical.

The part was made of pure nickel with a complex configuration featuring a unique internal discontinuous thread.

Suggested reading
Metal Injection Moulding: An alternative manufacturing process for aerospace applications?

As published in Vol. 13 No. 3, September 2019 (download PDF here)

The aerospace sector has long been recognised as an important potential market for the Metal Injection Moulding industry. However, extended application development cycles, combined with a lack of fundamental process understanding and rigorous validation requirements have, until now, held back the technology.

In the following article, Rolls-Royce’s Enrico Daenicke and Schunk Sintermetalltechnik GmbH’s Ingolf Langer report on the development of a new generation of high-performance MIM components that are now flying in Rolls-Royce aero engines: IN713LC superalloy stator vanes.

Next page: Applications: Consumer Products

Download PIM International magazine

In the latest issue of PIM International…

Download PDF

Extensive MIM, CIM industry and sinter-based AM industry news, plus the following exclusive deep-dive articles and reports:

  • INMATEC Technologies: Celebrating 25 years as a driving force behind Ceramic Injection Moulding
  • A year of change: Turbulence in China’s MIM industry as markets evolve
  • Ceramic Injection Moulding: The impact of variotherm and conformal cooling technology on part quality and process capability
  • The Additive Manufacturing of multi-material and multi-functional ceramic components

The latest news from the MIM, CIM and sinter-based AM industries

Don't miss any new issue of PIM International, and stay up to date with the latest industry news. Sign up to our fortnightly newsletter.

Sign up

Join our community

Discover our magazine archive…

The free-to-access PIM International magazine archive offers unparalleled insight into the world of MIM, CIM and sinter-based AM from a commercial and technological perspective through:

  • Reports on visits to leading part manufacturers and industry suppliers
  • Articles on technology and application trends
  • Information on materials developments
  • Reviews of key technical presentations from the international conference circuit
  • International industry news

All past issues are available to download as free PDFs or view in your browser.

 

Browse the archive

 

Looking for suppliers of materials, production equipment and finished MIM, CIM or sinter-based AM parts?

Discover suppliers of these and more in our advertisers’ index and buyer’s guide, available in the back of PIM International.

  • Metal powders
  • MIM, CIM & AM parts producers
  • Binders & feedstocks
  • Feedstock mixers
  • Furnaces & furnace supplies
  • Atmospheres & gas generation
  • HIP systems & services
  • Injection moulding machines
  • AM technology
  • Debinding systems
View online
Share via
Copy link
Powered by Social Snap