Microstructure and mechanical properties of powder-injection-molded products of Cu-based amorphous powders and Fe-based metamorphic powders

In the present study, a powder-injection molding (PIM) process was applied to Cu-based amorphous alloy powders and Fe-based metamorphic alloy powders, and microstructure, hardness, and wear resistance of the PIM products were analyzed and compared with those of conventional PIM stainless steel products. Injection-molded Cu-based amorphous powders were hardly sintered even at temperatures just below the melting temperature as most of amorphous phases were replaced by crystalline phases. When Fe-based metamorphic powders were injection-molded and then sintered at 1200 °C, completely densified products with almost no pores were obtained. They contained 34 vol.% of (Cr,Fe)2B borides dispersed in the austenitic matrix without amorphous phases. Since these (Cr,Fe)2B borides were very hard and thermally stable, hardness, high-temperature hardness, and wear resistance of the PIM products of Fe-based metamorphic powders were twice as high as those of conventional PIM stainless steel products. Such property improvement suggested new applicability of the PIM products of Fe-based metamorphic powders to structures and parts requiring excellent mechanical properties.