Efeito das variáveis de processamento em misturas de alumina com ligantes orgânicos usadas na moldagem por injeção em baixa pressão

Abstract

Low-pressure injection molding (LPIM) is a technique that has been used in the production of ceramic parts with complex shapes and geometries. The composition and homogeneity of the mixture of ceramic powder and organic binders are determining factors that must be controlled to minimize the defect formation in LPIM parts. Typical defects generated in LPIM processing, such as bubbles and agglomerates, form density gradients in the mixtures, that after molded, have a low probability of removal. These imperfections compromise the performance of the products obtained by this technique. Therefore, this work aims to evaluate the influence of process variables (such as mixers, the use or not of vacuum during the processing and mixing time), on the apparent density of green samples. It was also evaluated the influence of particle size distribution, the surface active agents and the percentage of carnauba wax on the rheological behavior of these mixtures. For that, purpose submicrometric alumina (as received and deagglomerated), was added to a molten binder mixture (based on paraffin wax and additives) and processed in two different mixers, with and without vacuum assistance. Furthermore, mixtures were prepared varying the composition, changing the surface active agent used or modifying the percentage of carnauba wax presents in the organic vehicle (O.V.). It was observed the presence of alumina agglomerates in the powder as received, possibly generated during the calcination step. It was also observed that the kind of the mixer and the application or not of vacuum during the final stage of process has a great influence on the density of green samples, as well as in the viscosity of feedstock for injection. Furthermore, it was observed that the mixture with two surface active agents (oleic acid and stearic acid) presents lower viscosity than only one surface active agent. Finally, the addition of carnauba wax reduces exponentially the viscosity of feedstock, allowing the possibility to increase the percentage of solids or reduce the time of processing, which can help in the production cost reduction of ceramic parts using the low-pressure injection molding method.