Fuel injector nozzle manufacturing method

Abstract

A method of manufacturing a fuel injector nozzle where a nozzle seat and a nozzle insert are made using a metal injection molding process. The nozzle seat and the nozzle insert are assembled and bonded together while in their green state. The resulting nozzle assembly is then debinded and sintered to obtain the desired fuel injector nozzle.

1 . A method of manufacturing a fuel injector nozzle comprising: 
 metal injection molding a nozzle insert in a green state;    metal injection molding a nozzle seat in a green state;    assembling the nozzle insert and the nozzle seat together while in their green states to obtain a nozzle assembly;    debinding the nozzle assembly; and    sintering the nozzle assembly.    
     
     
         2 . The method of  claim 1 , further comprising machining at least one of the nozzle insert and the nozzle seat while in their green states.  
     
     
         3 . The method of  claim 1 , wherein metal injection molding the nozzle insert and the nozzle seat is done simultaneously by using a common mold.  
     
     
         4 . The method of  claim 1 , further comprising bonding the nozzle insert and the nozzle seat together while in their green states prior to debinding the nozzle assembly.  
     
     
         5 . The method of  claim 4 , wherein bonding the nozzle insert and the nozzle seat together is done by using one of rotational welding, ultrasonic welding, and thermal welding.  
     
     
         6 . The method of  claim 1 , wherein debinding the nozzle assembly is done by using one of catalytic debinding, thermal debinding, and solvent debinding.  
     
     
         7 . A method of manufacturing a single part from multiple parts comprising: 
 metal injection molding a first part in a green state;    metal injection molding a second part in a green state;    assembling the first part and the second part together while in their green states to obtain an assembly;    debinding the assembly; and    sintering the assembly.    
     
     
         8 . The method of  claim 7 , further comprising machining at least one of the first part and the second part while in their green states.  
     
     
         9 . The method of  claim 7 , wherein metal injection molding the first part and the second part is done simultaneously by using a common mold.  
     
     
         10 . The method of  claim 7 , further comprising bonding the first part and the second part together while in their green states prior to debinding the assembly.  
     
     
         11 . The method of  claim 10 , wherein bonding the first part and the second part together is done by using one of rotational welding, ultrasonic welding, and thermal welding.  
     
     
         12 . The method of  claim 7 , wherein debinding the assembly is done by using one of catalytic debinding, thermal debinding, and solvent debinding.