Injection moulding of low expansion Fe-Ni-Co alloys

Low-expansion alloys (Fe-Ni-Co) are used in specific applications that require accurate dimensional control, such as standards for length measurement, radar resonant cavities, components for nuclear reactors and parts for ceramic-metal joining. This work investigates the production of the Fe-28%Ni-18%Co and Fe-28%Ni-23%Co alloys by powder injection moulding. The mixtures were characterised in the capilar rheometer. The microstructure was characterised with a scanning electron microscope and X-ray diffraction and the coefficient of thermal expansion determined with a linear dilatometer. The mixtures presented a pseudoplastic rheological behaviour and a viscosity level adequate to the injection moulding. The microstructure of the two alloys was constituted of an austenitic phase and the residual porosity (8.5%). Dilatometric behaviour of two alloys is characterised by two distinct regions, demonstrating the presence of the Invar effect and different transition temperature depending on the cobalt content. Coefficients of thermal expansion for both alloys can be considered adequate for brazing with alumina.