Binder Jetting of Silicon Steel, Part I: Process Map of Green Density

2021 ◽  
pp. 1-19
Author(s):  
Issa Rishmawi ◽  
Mihaela Vlasea
Keyword(s):  
Regression Model ◽  
Steel Part ◽  
Density Variation ◽  
Material System ◽  
Green Density ◽  
Spherical Powder ◽  
Green Part ◽  
Binder Saturation ◽  
Part Density ◽  
Binder Jetting

Abstract This study focuses on developing and demonstrating a straightforward workflow for identifying pathways to increase green part density in binder jetting additive manufacturing using statistically-driven process maps. The workflow was applied to investigate the effects of process parameters toward improving green part density, with a direct application in manufacturing of Fe-Si components. Specifically, a half-factorial experimental design was used to study the effects of four key parameters - layer thickness, powder spreading speed, roller rotational speed, and binder saturation - on Fe-Si spherical powder with D50 of 32.40 µm. The study discusses bulk density as well as localized density variation in the printed parts, which is attributed to both parameter selection and inherent process variability. A regression analysis was employed to reveal the significance of main effects and second order interactions. The regression model (R2 = 0.915) was used to derive an expression for green density as a function of the parameters, and had a prediction error of 0.96%. Based on the regression model, an optimized set of parameters was obtained that would maximize green density up to 57.96% for the machine and material system.

Effect of powder characteristics on parts fabricated via binder jetting process

2019 ◽  
Vol 25 (2) ◽  
pp. 332-342 ◽  
Author(s):  
Hadi Miyanaji ◽  
Niknam Momenzadeh ◽  
Li Yang
Keyword(s):  
Surface Roughness ◽  
Powder Particle Size ◽  
Particle Sizes ◽  
Material System ◽  
Size Distributions ◽  
Content Type ◽  
Powder Bed ◽  
Green Part ◽  
Powder Feedstock ◽  
Binder Jetting

PurposeThis study aims to experimentally investigate the effect of the powder material characteristics on the qualities of the binder jetting additive manufacturing parts both before and after post processing (sintering).Design methodology/approachThree different types of the 316L stainless steel powder feedstock with various mean particle sizes and size distributions were studied. The influence of the powder particle size distributions and pore sizes on the powder bed packing densities and on the dynamics of the binder droplet-powder bed interactions were characterized. In addition, the surface roughness and densities of these parts both in the green state and after sintering were studied.FindingsThe results revealed the significant role of the powder feedstock characteristics on the liquid binder/powder bed interaction and consequently on the dimensional accuracies of the green parts. It was observed that the parts printed with the smaller mean particle sizes resulted in better surface finish and higher final densities after sintering. Furthermore, the hardness of the sintered parts produced with smaller powder particles exhibited higher values compared to the parts fabricated with the larger particles. On the other hand, larger particle sizes are advantageous for various green part qualities including the dimensional accuracies, green part densities and surface roughness.Originality/valueThis study establishes more comprehensive correlations between the powder feedstock characteristics and various quality criteria of the printed binder jetting components in both green and sintered states. These correlation are of critical importance in choosing the optimal process parameters for a given material system.

Selective Laser Sintering of Zirconia

2000 ◽  
Vol 625 ◽  
Author(s):  
Nicole R. Harlan ◽  
David Bourell ◽  
Seok-Min Park ◽  
Joseph J. Beaman
Keyword(s):  
Selective Laser Sintering ◽  
Base Material ◽  
Laser Sintering ◽  
Average Density ◽  
Mold Material ◽  
Material System ◽  
Green Density ◽  
Stabilized Zirconia ◽  
Ceramic Components ◽  
Shock Resistance

AbstractA combination of Selective Laser Sintering and colloidal infiltration has been used to create partially stabilized zirconia molds for titanium casting. The mold material system was chosen for its low reactivity with molten titanium and thermal shock resistance. The base material, stabilized zirconia mixed with a copolymer binder, was pre-processed before laser sintering into the desired green shape. The average density of the fired parts could be increased to twice that of the green density. Hole sizes as small as 180 m are possible in thin ceramic components.

scholarly journals Density variation in binder jetting 3D-printed and sintered Ti-6Al-4V

2018 ◽  
Vol 22 ◽  
pp. 746-752 ◽  
Author(s):  
Erica Stevens ◽  
Samantha Schloder ◽  
Eric Bono ◽  
David Schmidt ◽  
Markus Chmielus
Keyword(s):  
Density Variation ◽  
3D Printed ◽  
Binder Jetting

Hydrothermal-Assisted Transient Binder Jetting of Ceramics for Achieving High Green Density

JOM ◽  
2019 ◽  
Vol 72 (3) ◽  
pp. 1307-1313
Author(s):  
Fan Fei ◽  
Li He ◽  
Baizhuang Zhou ◽  
Ziyang Xu ◽  
Xuan Song
Keyword(s):  
Green Density ◽  
Binder Jetting

Binder Jetting and Infiltration of Metal Matrix Nanocomposites

2021 ◽  
pp. 1-8
Author(s):  
Quinton Porter ◽  
Zhijian Pei ◽  
Chao Ma
Keyword(s):  
Metal Matrix ◽  
High Hardness ◽  
Green Density ◽  
Metal Matrix Nanocomposites ◽  
Liquid Infiltration ◽  
Complex Shapes ◽  
Dense Part ◽  
Superior Mechanical Properties ◽  
Matrix Nanocomposites ◽  
Binder Jetting

Abstract The ability to produce a dense part of Al-based metal matrix nanocomposites using binder jetting followed by infiltration was investigated. A green density above 1.58 g/cm3 was determined to be necessary for spontaneous direct liquid infiltration to commence, and a press-compaction-assisted binder jetting process is needed to achieve this benchmark. A green density of 1.64±0.02 g/cm3 only resulted in a density of 1.65±0.03 g/cm3 by sintering at 1050 °C, which showed that densification is not possible with sintering alone. However, infiltration with Al-6061 produced specimens with a density of 2.74±0.04 g/cm3, which corresponded to a density improvement of 65%. Moreover, the infiltrated specimens had a low open porosity of 2.71±0.95% and a high hardness of 54 HRA. This study suggests that it is feasible to manufacture parts with complex shapes and superior mechanical properties using binder Jetting followed by infiltration.

scholarly journals Binder Saturation, Layer Thickness, Drying Time and Their Effects on Dimensional Tolerance and Density of Cobalt Chrome- Tricalcium Phosphate Biocomposite

2021 ◽  
Author(s):  
Ruprecht John ◽  
Kuldeep Agarwal ◽  
Shaheen Ahmed
Keyword(s):  
Mechanical Properties ◽  
Layer Thickness ◽  
Tricalcium Phosphate ◽  
Biomedical Applications ◽  
Processing Parameters ◽  
Drying Time ◽  
Dimensional Tolerance ◽  
Binder Saturation ◽  
Binder Jetting ◽  
Cobalt Chrome

Traditional metals such as stainless steel, titanium and cobalt chrome are used in biomedical applications (implants, scaffolds etc.) but suffer from issues such as osseointegration and compatibility with existing bone. One way to improve traditional biomaterials is to incorporate ceramics with these metals so that their mechanical properties can be similar to cortical bones. Tricalcium phosphate is such a ceramic with properties so that it can be used in human body. This research explores the use of binder jetting based additive manufacturing process to create a novel biocomposite made of cobalt chrome and tricalcium phosphate. Experiments were conducted and processing parameters were varied to study their effect on the printing of this biocomposite. Layer thickness, binder saturation and drying time affected the dimensional tolerance and the density of the green samples. This effect is important to understand so that the material can be optimized for use in specific applications.

Process development for green part printing using binder jetting additive manufacturing

2018 ◽  
Vol 13 (4) ◽  
pp. 504-512 ◽  
Author(s):  
Hadi Miyanaji ◽  
Morgan Orth ◽  
Junaid Muhammad Akbar ◽  
Li Yang
Keyword(s):  
Additive Manufacturing ◽  
Process Development ◽  
Green Part ◽  
Binder Jetting

Effects of Injection Temperature and Pressure on Green Part Density for Ceramic Injection Molding

2012 ◽  
Vol 622-623 ◽  
pp. 429-432
Author(s):  
Sarizal Md Ani ◽  
Andanastuti Muchtar ◽  
Norhamidi Muhamad ◽  
Jaharah A. Ghani
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
High Density ◽  
Ceramic Injection Molding ◽  
Optimum Parameters ◽  
Green Part ◽  
Injection Temperature ◽  
Temperature And Pressure ◽  
Part Density ◽  
Zirconia Powders

This study investigates the effects of injection temperature and pressure on green part density. The high density of the green parts for the ceramic injection molding (CIM) process improves the material properties of the final product. In this study, the feedstock used was a combination of alumina and zirconia powders with a binder consisting of high density polyethylene, paraffin wax, and stearic acid. Powder loading was fixed at 57% volume. A standard screw-type injection molding machine was used to produce the green parts. The density of the green parts was measured using the Archimedes method. Experimental results show that a 160 °C injection temperature and a 110 MPainjection pressure were the optimum parameters to achieve high density of the green parts. In addition, defect-free green parts were obtained.

scholarly journals Compaction density variation in powder metallurgy components

2021 ◽  
Author(s):  
Elham Jafar-Salehi
Keyword(s):  
Finite Element ◽  
Powder Metallurgy ◽  
Density Distribution ◽  
Relative Density ◽  
Compaction Pressure ◽  
Density Variation ◽  
Fe Model ◽  
Green Density ◽  
Artificial Neural Network Ann ◽  
The Relationship

The main objective of this research was to study the relationship between green density and compaction pressure in powdered metallurgy. Powder metallurgy has gained popularity and importance because of its near net shape, cost effectiveness and its ability to reduce the complexity of multileveled engineering components. However, powder metallurgy poses challenges that are yet to be fully understood. There are many works performed to address challenges such as the effect of friction, the tool kinematics, handling component prior to sintering and fracture under compaction. This work concentrates on the relationship between green density distribution and compaction pressure. In order to measure the relative density of compacted components, Electron Scanning Microscope was utilized. One can intuitively conceive that the relative density requires more than intuition. It was determined that highest relative density occurs at the center of the specimen and reduces toward the die-powder or punch-powder boundary. For completeness, the application of artificial neural network (ANN) and finite element (FE) model in estimation of green relative density was studied. The results of this research signify that ANN is an excellent technique to determine the relative density distribution of un-sintered compacted specimen. Moreover, finite element method can accurately estimate the average relative density of compacted specimen.

Binder Jetting Additive Manufacturing of Ceramics: Analytical and Numerical Models for Powder Spreading Process

2019 ◽  
Author(s):  
Guanxiong Miao ◽  
Wenchao Du ◽  
Zhijian Pei ◽  
Chao Ma
Keyword(s):  
Additive Manufacturing ◽  
Numerical Models ◽  
Ceramic Materials ◽  
Low Density ◽  
Forming Process ◽  
Spreading Process ◽  
Powder Bed ◽  
Complex Shapes ◽  
Part Density ◽  
Binder Jetting

Abstract Binder jetting additive manufacturing is a promising way to process ceramic materials which are hard to be manufactured into complex shapes using conventional methods. However, the application of binder jetting is limited by the relatively low density of manufactured parts. Powder bed forming process is a critical step that determines the powder bed density and consequently the part density. Thus, investigating and understanding the power spreading process is necessary to improve the part density. A numerical model is developed to predict the powder bed density under different spreading conditions using the discrete element method (DEM). The predicted DEM results are compared with the prediction of an analytical model. The results show that under different layer thicknesses (50 μm, 70 μm, 100 μm) and roller diameters (12 mm, 14 mm, and 16 mm), the predicted maximum powder bed density by these two models has nearly the same value and the predicted maximum packing stress has the same trend.

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