一、Applicable Scenarios for Metal Forming Processes(MIM)
Aluminum alloy powder injection molding(MIM) technology is particularly suitable for:Thin-walled components unsuitable for die casting Complex small parts where CNC machining is cost-ineffective Appearance parts requiring multiple surface treatments
MIM Current primary applications:
Transmission components / pinions / synchronous pulleys
Metal parts for 3C (Computer, Communication, Consumer electronics) industry
Heat sinks and cooling fans
Consumer product appearance parts
二、Performance Parameters of Aluminum Alloy Injection Molding
| Performance Indicator | As-sintered | T6 Treated | Wrought Plate |
|---|---|---|---|
| Density (g/cm³) | 2.68±0.01 | 2.68±0.01 | 2.70-2.73 |
| Vickers Hardness (HV) | 40-50 | 100-120 | 86-110 |
| Yield Strength (MPa) | 50-78 | 290-320 | 55-245 |
| Tensile Strength (MPa) | >158 | >335 | 124-265 |
| Elongation (%) | 20-26 | >6 | 25/8 |
| Salt Spray Test | Pass 48h | - | Pass |
Dense, fine and uniform microstructure is the basis of high density, high strength and anodization
三、Performance Comparison: 6061 Injection Molding vs. Traditional Processes
| Manufacturing Process | Tensile Strength (MPa) | Yield Strength (MPa) | Elongation (%) |
|---|---|---|---|
| MIM6061-T6 | 366.8 | 317.4 | 11.6 |
| Gravity Casting-T6 | 266.2 | 258.3 | 11.5 |
| Squeeze Casting-T6 | 271.8 | 261.3 | 11.3 |
| Forging-T6 | 310 | 276 | 12 |
| Metal 3D Printing-T6 | 308 | 282 | 3.5 |
Key Findings:
6061-T6 tensile strength (366.8 MPa) exceeds gravity casting by 37.8%
Elongation (11.6%) significantly outperforms metal 3D printing (3.5%)
Yield strength (317.4 MPa) approaches forging process levels (276-310 MPa)
四、Process Selection Guidelines
Consider Injection Molding when:
Complex geometries required (gears, thin-walled parts)
Multiple surface treatments needed (e.g., anodizing)
Medium-to-high volume production (≥500 pieces)
Salt spray 48h certification required
Choose traditional processes when:
Oversized components (beyond current MIM capabilities)
Extremely low-volume production (<500 pieces)
Simple structural parts without surface treatment requirements