Method for co-processing components in a metal injection molding process, and components made via the same

Abstract

Described herein is a method comprising molding a first component from a first feedstock comprising a first material powder and a first binder, molding a second component from a second feedstock comprising a second material powder and a second binder, placing the first component and the second component in physical communication with each other in order to form an assembled component, removing the first binder and the second binder from the assembled component and performing a sintering operation on the assembled component so as to bond the first component and the second component together.

What is claimed is: 
     
         1 . A method, comprising:
 molding a first component from a first feedstock comprising a first material powder and a first binder;   molding a second component from a second feedstock comprising a second material powder and a second binder;   placing the first component and the second component in physical communication with each other in order to form an assembled component;   removing the first binder and the second binder from the assembled component; and   performing a sintering operation on the assembled component so as to bond the first component and the second component together.   
     
     
         2 . The method of  claim 1  further comprising, applying a bonding agent to at least a mating surface of the first component or a mating surface of the second component prior to placing the first component and the second component in physical communication, wherein the mating surface of the first component is in contact with the mating surface of the second component. 
     
     
         3 . The method of  claim 2 , wherein the bonding agent comprises at least one of polymeric binding agent, a non-polymeric bonding agent, or a carboxylic acid, wherein,
 the polymeric binding agent is preferably at least one of PEG, polypropylene, or polyethylene, and   the carboxylic acid is preferably a saturated or an unsaturated fatty acids such as oleic acid.   
     
     
         4 . The method of  claim 1 , wherein at least one of the first component or the second component comprises a hollowed portion such that an interior cavity is formed in the assembled component upon placing the first component and the second component in physical communication. 
     
     
         5 . The method of  claim 1 , wherein the first component comprises a first reference feature and the second component comprises a second reference feature, said method further comprising placing the first component and the second component in physical communication with each other such that the first reference feature and the second reference feature are positioned in a predetermined manner in relation to each other. 
     
     
         6 . The method of  claim 1  further comprising, preparing the first feedstock prior to molding the first component and preparing the second feedstock prior to molding the second component. 
     
     
         7 . The method of  claim 6 , wherein the first feedstock and the second feedstock are the same. 
     
     
         8 . The method of  claim 6 , wherein the first feedstock and the second feedstock are different. 
     
     
         9 . The method of  claim 6 , wherein:
 preparing the first feedstock comprises selecting the first material powder based at least in part on desired properties of the first component, and   preparing the second feedstock comprises selecting the second material powder based at least in part on desired properties of the second component.   
     
     
         10 . The method of  claim 6 , wherein:
 preparing the first feedstock comprises selecting a particle size for the first material powder based at least in part on a melting temperature of the first material powder,   preparing the second feedstock comprises selecting a particle size for the second material powder based at least in part on a melting temperature of the second material powder, and   the particle size of the first material powder and the particle size of the second material powder are selected such that the first material powder and the second material powder melt at approximately the same temperature.   
     
     
         11 . The method of  claim 1 , wherein the first material powder and the second material powder are different, and the first binder and the second binder are the same. 
     
     
         12 . The method of  claim 1 , wherein the first feedstock further comprises a space-holder. 
     
     
         13 . The method of  claim 12  further comprising, removing the space-holder to form a porous space once occupied by the space-holder, wherein removing the space-holder occurs after molding of the first component from the first feedstock and prior to removing the first binder and the second binder from the assembled component. 
     
     
         14 . The method of  claim 12 , wherein removing the space-holder occurs using one of a solvent removing process or a thermal removing process. 
     
     
         15 . The method of  claim 1 , wherein debinding is performed by at least one of a thermal debinding technique or a solvent debinding technique. 
     
     
         16 . The method of  claim 1 , wherein the first component and the second component are molded via a metal injection molding process. 
     
     
         17 . A method, comprising:
 molding a first component from a first feedstock comprising a first material powder and a first binder;   preparing a mating surface of the first component;   inserting the first component into a mold of a second component;   molding the second component from a second feedstock comprising a second material powder and a second binder to form an assembled component with the second component at least partially surrounding the first component;   removing the first binder and the second binder from the assembled component; and   performing a sintering operation on the assembled component so as to bond the first component and the second component together.   
     
     
         18 . The method of  claim 17  further comprising, preparing the first feedstock prior to molding the first component and preparing the second feedstock prior to molding the second component, wherein
 preparing the first feedstock comprises selecting the first material powder based at least in part on desired properties of the first component, and 
 preparing the second feedstock comprises selecting the second material powder based at least in part on desired properties of the second component. 
 
     
     
         19 . The method of  claim 17 , wherein at least one of the first feedstock or the second feedstock comprises a space-holder. 
     
     
         20 . The method of  claim 19  further comprising, removing the space-holder to form a porous space once occupied by the space-holder, wherein
 removing the space-holder from the first feedstock occurs after molding of the first component from the first feedstock and prior to molding the second component, and 
 removing the space-holder from the second feedstock occurs after molding of the second component from the second feedstock and prior to removing the first binder and the second binder from the assembled component.