Fuel Injectors, Sensors and Actuators Manufactured by Bi-Metal Powder Injection Molding 2002-01-0343

Two-material combinations to form a single component are possible by welding or brazing, but a more cost-effective and higher quality means is to assemble small pieces into the final integral shape during initial forming. If sintering is controlled, then the final object has an integral metallurgical bond, yet functionality within that component that is placed to the designer needs. Although tooling is more expensive for bi-metal molding, automotive applications justify the set-up expense of this new metal powder injection molding process. Candidate applications are associated with selective function as desired, such as in sensors, actuators, fuel injectors, and wear components. The scale-up of the process is demonstrated with several geometries and applications.