Nano-particles in powder injection molding of an aluminum matrix composite: Rheological behavior, production and properties

Abstract Feedstocks containing 54 and 60 vol.% powder loadings were prepared using a multi-component binder and different amounts of nano-alumina (0–9 wt.%). Feedstock containing 60 vol.% powder and 6 wt.% nano-alumina had the lowest shear rate sensitivity (n). The Al feedstocks containing nanoparticles were injected, de-bound and sintered. The rate of solvent de-binding for samples containing nano-particles was slightly lower than that of similar specimens. Results showed that nano-scale additive caused increased relative density, hardness and strength of manufactured composites, but decreased shrinkage and grain size. The composite with 54 vol.% powder loading and 9 wt.% nano-alumina had the best evaluations for mechanical properties. Particle clustering caused a decline in all evaluations for mechanical properties for 60 vol.% powder loading and 9 wt.% nano-alumina sample.