Exploitable results Development of porcelain waste materials for the fabrication of components by injection moulding; RECIM PROJECT Formulations of feedstocks have been tested with recycled and non recycled porcelain and commercial and new binders in the injection moulding process into the fast firing process. The main results obtained in this project are as follows: SCIENTIFIC RESULTS - Incorporation of recycled porcelain: 9 different porcelain powder compositions. These powders contains different ranges of recycled porcelain between 0 and 100%. Three selected feedstocks contains 0, 50 and 80% of recycled porcelain respectively. - Binders.- 18 feedstocks containing new binders were tested. A commercial binder (VP3619-Bayer) were selected between from a group of six binders (Product 6042 and Siliplast HS from Z&S, Hostamont TP EK 583 from Hoechst, VPAI 3617, 3574 and 3619 from Bayer) - Evaluation of rheology properties of porcelain feedstocks.- 111 feedstocks were evaluated. Three candidates were selected from this group (F99, F95 and F108) .Only the references F95 & F108 & AF1-AF4 have recycled porcelain, but only good shaped pieces have been obtained with F99 & AF3 & AF4 . TECHNOLOGIC RESULTS - Setting up a pilot plant.- A semindustrial pilot plant were setting up at LEPSA. This plant contains: Injection moulding machine, Robot to handle parts, and Non destructive examination control station. The automation of the process it is viable when the previous stage are well defined. - Procedure for milling and mixing porcelain powders.- KPCL have developed milling and mixing conditions for powders formulations in the project. - Procedure for preparing feedstock.- KPCL have developed the procedure for mixing binders with porcelain powders containing different amounts of recycled material. - Procedure for designing pieces adapted to PIM. LEPSA had got experience to design the geometry of the pieces for PIM . The design of the mould has to be taken in account the behaviour of the material during the injection and debinding process. The width of the wall has to be < 10 mm, and the design of the handles has to take care with the geometry , weight and flexural strength. - Procedure for building moulds.- SoarMoldes have got experience building moulds for porcelain injection moulding. Cup and jar moulds prototypes that have been optimize after testing with different feedstocks. The mould has to be ion implanted to elongate his wife, and to have a hot nozzle to reduce the weld-marks. - Procedure for injection moulding.- Inasmet and LEPSA have optimized injection parameters for different feedstocks and moulds used in the project and have determined some of the most critical parameters related to the pression -postpression and temperature control. - Procedure for debinding.- The debinding process is very critical , it requires a good control in regulations and depends a lot of on the width of the piece : it is critical the relationship of the design and the debinding cycles in order to reduce times of processing and costs. According to thickness wall of parts INASMET have design different debinding cycles for selected feedstocks and LEPSA has adjusted them for prototype pieces.. LEPSA have optimized solutions to support parts at debinding process . - Procedure for glazing and firing.- LEPSA have defined the best parameters for glazing and firing of candidates feedstocks. - Procedure for testing.- INASMET have set up methodologies for testing binders, feedstocks and injected parts after mixing, injection, debinding and firing steps , KPCL & LEPSA powders Searching for OpenAIRE data... There was an error trying to search data from OpenAIRE No results available
