Method for making molybdenum parts using metal injection molding

A method for making a molybdenum part, comprising:

• injection molding a feedstock to form a green-state part, the feedstock comprising molybdenum powder and at least one binder;
• debinding the green-state part to remove at least 40% of the binder to form a brown-state part;
• and
• sintering the brown-state part at a peak temperature of no greater than about 3000° F.

A method for making a molybdenum part, comprising:

• forming a feedstock by mixing a metal powder and a binder, and heating the mixture to a temperature sufficient to cause the binder to melt, wherein the metal powder consists of molybdenum and has a particle size of no greater than about 5 microns, and the binder comprises at least 60% by volume of the feedstock;
• injection molding the feedstock to form an unsintered part;
• placing the unsintered part on an inner surface of a first setter, the inner surface being generally contoured to the shape of an adjacent surface of the part in contact with the inner surface, the first setter being formed from a feedstock formed from molybdenum powder and a binder;
• debinding the unsintered part by placing the part and the first setter in a bath of at least one solvent;
• placing a second setter on the unsintered part with an inner surface of the second setter contacting an adjacent surface of the part opposite the first setter, the inner surface of the second setter being generally contoured to the shape of the adjacent surface of the part contacting the second setter, the second setter being formed from a feedstock formed from molybdenum powder and a binder;
• and
• sintering the unsintered part.