Abstract
Two-material combinations to form a component are possible by welding or brazing, but a more cost-effective means for small components is to perform the assembly using powder injection molding and a new concept termed bi-metallic molding. This requires two materials (feedstocks) be formed sequentially into a molding cavity, and then the two materials must co-sinter to full density. Several automotive applications justify the expense of bimetal powder injection molding, assuming the sintering process can be optimized. Candidate applications are associated with sensors, actuators, and wear components. The scale-up is demonstrated with several geometries and property combinations.
