Powder injection molding of a mullite–zirconia composite

Mullite–zirconia composites have been identified as a potential material for high-temperature structural applications due to high-temperature strength, thermal shock resistance, and low coefficient of thermal expansion. In the present study, the feasibility of using powder injection molding to fabricate parts from a mullite–zirconia composite was investigated. The properties of the developed feedstock were used to simulate and identify suitable molding conditions for fabricating parts like miniature turbine stators. A test coupon was successfully injection molded from the developed feedstock. The results from the study confirm the ability of powder injection molding to fabricate complex shapes made from mullite–zirconia composites.