Dr. Stephen C. Bates

P.O. Box 1310

Glastonbury, CT 06033

Research has been performed to develop a new binder that will allow powder metal injection molding (MIM) of reactive metal parts. Parts made of reactive metals such as titanium are already extensively made using powder metallurgy, but many valuable metals are so reactive at high temperature that any currently available binder will react with and contaminate the part during MIM processing. The development of the new binder parallels that of other binders, modified by the conditions of its formation as well as its physical and debinding characteristics that fundamentally change its behavior as a binder. Binder properties, the binder/powder ratio, the mixing procedure, the injection molding process, and the debinding process have been explored experimentally to optimize the process using titanium as the reactive metal powder. Rudimentary injection molding tests have been performed, demonstrating the practicality of the basic technique, but adequate green strength needs to be demonstrated, as well as the economics of the overall process. The technique may be even more attractive slip casting parts.