Rheology of Highly Concentrated Suspensions with a Bimodal Size Distribution of Solid Particles for Powder Injection Molding

Powder injection molding (PIM) is one of the modern and prospective technologies in processing different materials. We proposed to use bimodal compositions of particles for increasing their content in the final products. A set of model suspension of Al with low-molecular-weight poly (ethylene glycol) as a binder based on theoretical arguments concerning the filling capacity of bimodal suspensions was prepared. Studying the rheological properties of these compositions showed that they demonstrate elasto-viscous behavior with significant plasticity that is favorable for the technological process. Using compositions with bimodal distributions allows for increasing the content of the solid phase up to 75 vol. % for PIM technology, which is significantly higher than the standard practical limit. This rheological approach developed for model formulations was applied to processing compositions containing aluminum oxide as typical ceramics and polyolefines as a binder widely used in technological practice. The obtained sintered ceramic samples have quite acceptable mechanical properties of the usual corundum articles.