| Summary: | Metal Injection Moulding (MIM) is an effective near-net-shape process for producing small, intricate parts in high volumes. Many optimizations of the MIM process parameter have been published without using any of the statistical based Design of Experiment (DOE) methodology and ends with unsatisfactory results in a wide range of experimental settings. This paper focuses on analysing the optimization of injection moulding process parameters for titanium alloy Ti-6Al-4V green parts using response surface methodology (RSM) to determine significant parameters. The feedstock is prepared by mixing Ti-6Al-4V powder with palm stearin (PS) and polyethylene (PE) binders in three different powder loadings: 63 vol%, 65 vol%, and 67 vol%. RSM is then used to create a Design of Experiment (DOE) to optimize parameters, including A: injection pressure, B: injection temperature, C: powder loading, D: mould temperature, and E: holding pressure. Analysis of variance (ANOVA) was performed to identify the significant parameters influencing defects in Ti-6Al-4V green parts. The study successfully identified the optimal conditions for producing Ti-6Al-4V components using PS and PE binders: A: 443.139 bars, B: 142.11 ºC, C: 65.38 vol.%, D: 44.694 ºC, and E: 629.561 bar. Scanning electron microscopy (SEM) from optimised of green part shows that the primary backbone polymer PE holds the green part and generates wetting for the feedstock and will ease moulding and shaping while the secondary backbone PS will act as a soft polymer that can provide the moisture to the feedstock. © 2024, University of Ilorin, Faculty of Engineering and Technology. All rights reserved.
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