This study investigates the effects of repetitive injection molding on the properties of feedstock using the AISI 4140 feedstock. The properties of feedstock are evaluated from the mixing homogeneity of powder and binder, rheological properties, and dimensional accuracy of parts sintered. The feedstock after the 1st injection molding shows a better homogeneity than as-received feedstock due to re-mixing effects between the screw and barrel during the injection molding process. As the number of recycling numbers increases, the homogeneity, viscosities ad shrinkage ratio of recycled feedstocks show slight differences with those of the as-received feedstock until the 6th molding injection. However, some rheological parameters like the moldability index sharply increased up to the 4th injection but shows a tendency to decrease thereafter.

In this study, decomposition and densification behavior of PbAlNbO3-PbZrTiO3 (PAN-PZT) ceramics were characterized for powder injection molding process. Thermal gravity analysis and in-situ dilatometer experiment were carried out to construct master curve. Based on master curve model approach, one-combined master debinding curve (MDC) and master sintering curve (MSC) were constructed for piezoelectric PAN-PZT ceramics. Derived curves matched well with the experimental data. Process optimization and material development will be conducted based on characterization of master curve parameters.