Towards High-Density and Thick-Walled NiFe2O4-based Cermet by Ceramic Injection Molding Using Spherical Composite Powder

Ceramic injection molding (CIM) is a near-net-shape technology for the rapid manufacture of complex-shaped small parts. Preparation of thick-walled parts remains a challenge owing to the difficulty in debinding process for green body based on micron and irregular ceramic powders. In this study, spherical metal-ceramic composite powders with different particle sizes were prepared using a wet granulation method. NiFe2O4-based cermets with a thickness of 20 mm were fabricated using both spherical (SP) and non-spherical (NSP) powders as raw materials. Roles of the powder shapes in catalytic debinding and sintering behaviour were investigated. Compared with that of NSP, green body with SP exhibited improved debinding efficiency, due to the well developed pore channels. A new perspective was proposed to explain the mass transfer mechanism during the debinding process. The adoption of spherical composite powders significantly enhanced the debinding rate without affecting the sintering performance. After sintering, sound cermet parts with uniform microstructure and the highest relative density of 98.62 % were achieved. This provides an important reference for the fabrication of large and thick-walled parts by CIM via controlling the powders.