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 Case
Study # 3
Component:
DRO
Housing
Challenge: This defibrillating
resonating oscillator was growing in volume requirements.
Traditionally machined because of low quantities,
challenges to reduce cost while maintaining precision, hermiticity,
and the same co-efficiency of thermal expansion were presented to
FloMet.
Solution:
A
CTE tailored Fe Ni feedstock was developed for the application.
The customer and FloMet worked together to create a part
with minimum weight.
No machining, incorporation of additional features that had
been separate assembly parts attained a superior level of Tekna
Seal finished hermeticity.
Telecommunication
and other microelectronic devices need to be protected by being
sealed in a hermetic package.
This housing is used in a microwave telecom application.
It was originally developed by machining of a popular Fe
49% Ni alloy. The
material is expensive to throw away chips, and is “tough and
gummy” to machine also.
FloMet
worked with the customer to convert the part to MIM manufacture
substantially reducing the weight by net shape fabrication.
Also, no chip MIM fabrication reduced overall product
material cost. A feedstock was developed using Fe Ni that repeats the CIE of
the original wrought alloy. Another
added benefit was the shape incorporation of the threaded posts
that had been separated “stand offs” with longer bolts through
them, reducing assembly components.
All eight threaded holes were molded into the part.
FloMet
went to (1)Teka Seal, a glass-to-metal sealer under the same
ownership as FloMet, to complete the glass-to-metal sealing and
feed through pin assembly. Final
nickel/gold plating was subcontracted as the only outside
secondary operation.
When
sintered, the part was in excess of 98% density.
When finished by Tekna Seal, the hermeticity was tested by
an independent certifying lab and found to be less than 2.0 x 10-10.
atm cc/sec of helium. This
is better than twice the order of magnitude of the point
specification.
MIM
achieved the cost target by greater than 60% of the original
wrought design.
http://www.teknaseal.com/
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