This article commences with a discussion on the qualitative and quantitative criteria for metal injection molding (MIM), including production quantities, shape complexity, material performance, and cost. It discusses geometric factors, such as surface finish, component size, and mass range, which help to identify a component for MIM. The article describes certain part features, including holes, undercuts, and flat faces. It concludes with a discussion on the common materials used in MIM; tensile properties of 17-4 PH stainless steel MIM, cast and wrought products; and attributes of the MIM process.

This article discusses continuum modeling, which is the most relevant approach in modeling grain growth, densification, and deformation during sintering. Continuum plasticity models are frequently used to describe the mechanical response of metal powders during compaction. The article illustrates the typical procedure for computer simulation for press and sinter process. It describes the procedure to obtain the material properties based on the generalized Shima-Oyane model. The article presents a wide variety of tests, accounting for data on the grain growth, densification, and distortion where these data help in the development of a constitutive model for sintering simulation. Finally, the article provides information on the simulation approaches used to optimize die compaction and sintering.

This article presents the governing equations and methodologies to model the press and sinter powder metallurgy, including continuum, micromechanical, multiparticle, and molecular dynamics approaches. It describes the constitutive relation for compaction and sintering. The article discusses the experimental determination of material properties and simulation verification for compaction and sintering. It reviews the use of modeling and simulation of press and sinter powder metallurgy, including gravitational distorting in sintering, compaction optimization, sintering optimization, and coupled press and sinter optimization.

This article focuses on the axisymmetric 2.5-dimensional approach used in metal powder injection molding (PIM) simulations. It describes three stages of PIM simulations: filling, packing, and cooling. The article discusses the process features of numerical simulation of PIM, such as filling and packing analysis, cooling analysis, and coupled analysis between filling, packing, and cooling stages. It explains the experimental material properties and verification for filling, packing, and cooling stages in the PIM simulations. The article presents simulation results from some of the 2.5-dimensional examples to demonstrate the usefulness of the computer-aided engineering analysis and optimization capability of the PIM process.

This article discusses the fracture and fatigue properties of powder metallurgy (P/M) materials depending on the microstructure. It describes the effects of porosity on the P/M processes relevant to fatigue and fracture resistance. The article details the factors determining fatigue and fracture resistance of P/M materials. It reviews the methods employed to improve fatigue and fracture resistance, including carbonitriding, surface strengthening and sealing treatments, shot-peening, case hardening, repressing and resintering, coining, sizing, and postsintering heat treatments. Safety factors for P/M materials are also detailed.