Influence of powder characteristics on the behaviour of PIM feedstock

•Influence of agglomerated powder on the feedstock's behaviour is studied.•Implementations reveal different behaviours during mixing according to the powder.•Influence of the powder characteristics on the mixing step is performed.•The powders perfectly satisfy the criteria imposed by the mixing process. This work aims to analyse the impact of powders which are not conventionally intended for powder injection moulding (PIM) and how their characteristics influence the behaviour of the feedstock during mixing. Tests were performed with different alumina powders using the same binder system. The results show that mixing has a strong impact on the packing density of powders inside the feedstock, while the deagglomeration of powders makes it possible to achieve high critical powder volume concentrations (CPVCs) equal to or greater than 58vol%. The CPVC depends on the deagglomeration efficiency. The agglomeration state – especially cohesion of the agglomerates – has an influence on the CPVC. The comparative study of mixing torques shows that the grain size and surface area of powders have a major impact on the mixing behaviour of the feedstock. During the implementation of powders, variabilities in the homogenisation of the powder/binder system and in deagglomeration are achieved as a result of powder agglomeration. It was demonstrated that the powders in this study perfectly satisfy the criteria imposed by the mixing process although they are not intended for PIM.