Debinding of injected parts using an abnormal glow discharge

Results of binder removal of injected PM components using plasma technology are presented. The samples were injected with 55.18 vol.% of iron powder, 23.57 vol.% of paraffin and 21.25 vol.%. of polypropylene and treated in hydrogen and argon discharges at a pressure of 400 Pa (3 Torr), varying temperature and treatment times. The discharge was generated by a pulsed power source in a confined anode–cathode geometry. The outer electrode consisted of the cathode and was heated by the bombardment of ions accelerated in the cathode region. The sample was placed on an inner holder and heated by thermal radiation. Three different configurations of electrodes were used in order to evaluate the influence of electron bombardment on the sample surface, the interaction of the reactive species generated in the discharge with the binder and thermal effects on the dissociation of the organic molecules. Samples were characterized by mass loss and energy dispersive X-ray (EDX) analysis. The results show that the electron bombardment added to the interaction of reactive species on the sample surface significantly activated the binder removal. By using a laboratory scale plasma reactor, it was shown that the binder extraction and pre-sintering cycle could be performed in a single thermal cycle lasting approximately 200 min.