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The metal injection molded One Piece Nozzle has pushed this technology to greater heights. It is an impossible task to produce this product near net shape using other conventional methods. Possible methods will be brazing of multiple machined components, which will end up with high material wastage and high cost. The MIM One Piece Nozzle produced good finish with complex internal channel in a sustainable and economical way. This product has open up an entirely new application for MIM process capability, and definitely the most complex part that we have ever produced.
Development efforts were focus on controlling the distortion of the plastic inserts during metal injection molding, as high injection pressure and temperature will greatly affect the insert integrity. On the contrary, we need to maintain high packing pressure in the inner core channel, as any loss in pressure will encourage weakness resulting in cracks. Finding the ideal injection parameters that resulted in overall good part were highly challenging during development phase. The other critical feature is the tip of the nozzle, the diameter of the hole and gap surrounding it are controlled in micron range which are MIM without secondary operations. Looking at the cross-section you will understand the critical features were achieved with great definition.
The One Piece Nozzle is applied in a Selective Catalytic Reduction (SCR) system for commercial vehicles in Europe to comply with the Euro 5 and Euro 6 standards. Urea is connected to the center through hole, and compressed air is connected to the other channel. The compressed air is pumped into the nozzle exiting though the "ring" at the nozzle tip, this generates a low pressure region at the tip producing a venturi effect. This will draw out the urea from the middle channel and spray onto the SCR system, which will reduce the exhaust NOx to N2 and H2O.
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