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.

Binder Jetting Additive Manufacturing of Metals: A Literature Review

2019 ◽  
Author(s):  
Ming Li ◽  
Wenchao Du ◽  
Alaa Elwany ◽  
Zhijian Pei ◽  
Chao Ma
Keyword(s):  
Additive Manufacturing ◽  
Dimensional Accuracy ◽  
Binding Agent ◽  
Metal Part ◽  
Spreading Process ◽  
Powder Bed ◽  
The Past ◽  
Wide Range ◽  
Binder Jetting ◽  
Two Parameter

Abstract Binder jetting, also known as 3D printing, is an additive manufacturing (AM) technology utilizing a liquid-based binding agent to selectively join the material in a powder bed. It is capable of manufacturing complex-shaped parts with a variety of materials. This paper provides an overview of binder jetting of metals with a discussion about the knowledge gaps and research opportunities. The review deals with two parameter categories in terms of the material and process and their impacts. The achieved density, dimensional accuracy, and mechanical strength are summarized and analyzed. Further in-depth consideration of densification is discussed corresponding to various attributes of the packing, printing, and sintering behaviors. Though binder jetting has attracted increasing attention in the past several years, this fabrication process is not well studied. The understanding of powder spreading process and binder-powder interaction is crucial to the development of binder jetting but insufficient. In addition, the lack of investigation on the mechanical behavior of binder jetting metal part restricts the actualization of its wide-range applications.

A Review on Additive Manufacturing of Ceramics

2019 ◽  
Author(s):  
Brooke Mansfield ◽  
Sabrina Torres ◽  
Tianyu Yu ◽  
Dazhong Wu
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Computer Aided Design ◽  
Ceramic Materials ◽  
Complex Geometries ◽  
Laminated Object Manufacturing ◽  
Challenges And Opportunities ◽  
Aided Design ◽  
Binder Jetting

Abstract Additive manufacturing (AM), also known as 3D printing, has been used for rapid prototyping due to its ability to produce parts with complex geometries from computer-aided design files. Currently, polymers and metals are the most commonly used materials for AM. However, ceramic materials have unique mechanical properties such as strength, corrosion resistance, and temperature resistance. This paper provides a review of recent AM techniques for ceramics such as extrusion-based AM, the mechanical properties of additively manufactured ceramics, and the applications of ceramics in various industries, including aerospace, automotive, energy, electronics, and medical. A detailed overview of binder-jetting, laser-assisted processes, laminated object manufacturing (LOM), and material extrusion-based 3D printing is presented. Finally, the challenges and opportunities in AM of ceramics are identified.

scholarly journals Study and Application Status of Additive Manufacturing of Typical Inorganic Non-metallic Materials

2019 ◽  
Vol 26 (1) ◽  
pp. 58-70
Author(s):  
Yu YUN ◽  
Tingchun SHI ◽  
Yonghui MA ◽  
Fangfang SUN ◽  
Jinde PAN ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Material Handling ◽  
Hot Spot ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Ceramic Materials ◽  
Metallic Materials ◽  
Forming Process ◽  
Forming Characteristics ◽  
And Performance

Additive manufacturing is a rapid manufacturing based on discrete accumulation to achieve prototypes or parts of products. Inorganic non-metallic materials, as one of the three major materials, have incomparable application prospect in medical, aerospace, automotive, construction, arts and crafts, as well as many other fields. In order to rapidly create devices with arbitrarily complex shapes, additive manufacturing of inorganic non-metallic materials is becoming a hot spot of current research. In view of the technical types, materials and other aspects, this article introduced research status and development of additive manufacturing in inorganic non-metallic materials at home and abroad. Several common inorganic non-metallic materials are compared and analyzed, such as Al2O3, Si3N4 SiO2, ZrO2, etc. The forming characteristics and the problems of several popular ceramic materials and sand–casting materials are illustrated with emphases. The key problems existed in additive manufacturing forming process of inorganic non-metallic material are pointed out and urgent to be solved at present. Furthermore, the impacts of the material handling process, three dimensional printing (3DP), Selective Laser Sintering(SLS), Selective Laser Melting (SLM) three-dimensional forming processes and post treatment process on the quality and performance of the forming parts are analyzed. Finally, the prospects in SLS of the gem material are put forward.

Wire + Arc Additive Manufacturing of Metals

2020 ◽  
pp. 106-126
Author(s):  
Krishna Kishore Mugada ◽  
Aravindan Sivanandam ◽  
Ravi Kumar Digavalli
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Manufacturing Sector ◽  
Manufacturing Processes ◽  
Deposition Rates ◽  
Direct Energy Deposition ◽  
Powder Bed ◽  
Direct Energy ◽  
Wire Arc Additive Manufacturing ◽  
Binder Jetting

Wire + Arc additive manufacturing (WAAM) processes have become popular because of their proven capabilities to produce large metallic components with high deposition rates (promoted by arc-based processes) compared to conventional additive manufacturing processes such as powder bed fusion, binder jetting, direct energy deposition, etc. The applications of WAAM processes were constantly increasing in the manufacturing sector, which necessitates an understanding of the process capability to various metals. This chapter outlines the significant outcomes of the WAAM process for most of the engineering metals in terms of microstructure and mechanical properties. Discussion on various defects associated with the processed components is also presented. Potential application of WAAM for different metals such as aluminum and its alloys, titanium, and steels was discussed. The research indicates that the components manufactured by the WAAM process have significant microstructural changes and improved mechanical properties.

On the effect of irradiance on dimensional accuracy in multijet fusion additive manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Mattia Mele ◽  
Giampaolo Campana ◽  
Gian Luca Monti
Keyword(s):  
Additive Manufacturing ◽  
Dimensional Accuracy ◽  
Crystallinity Degree ◽  
Content Type ◽  
Powder Bed ◽  
Polyamide 12 ◽  
Part Density ◽  
The Relationship ◽  
Am Processes

Purpose The amount of radiated energy is known to be a crucial parameter in powder-bed additive manufacturing (AM) processes. The role of irradiance in the multijet fusion (MJF) process has not been addressed by any previous research, despite the key role of this process in the AM industry. The aim of this paper is to explore the relationship between irradiance and dimensional accuracy in MJF. Design/methodology/approach An experimental activity was carried out to map the relationship between irradiance and dimensional accuracy in the MJF transformation of polyamide 12. Two specimens were used to measure the dimensional accuracy on medium and small sizes. The experiment was run using six different levels of irradiance. For each, the crystallinity degree and part density were measured. Findings Irradiance was found to be directly proportional to part density and inversely proportional to crystallinity degree. Higher irradiance leads to an increase in the measured dimensions of parts. This highlights a predominant role of the crystallisation degree and uncontrolled peripherical sintering, in line with the previous literature on other powder-bed AM processes. The results demonstrate that different trends can be observed according to the range of sizes.

Binder Jetting Additive Manufacturing of Ceramics: A Literature Review

2017 ◽  
Author(s):  
Wenchao Du ◽  
Xiaorui Ren ◽  
Chao Ma ◽  
Zhijian Pei
Keyword(s):  
Additive Manufacturing ◽  
Literature Review ◽  
Process Parameters ◽  
Material Properties ◽  
Raw Materials ◽  
High Hardness ◽  
Ceramic Materials ◽  
Future Research ◽  
Binder Jetting ◽  
Resultant Material

Ceramic materials are more difficult to process than metals and polymers using additive manufacturing technologies because of their high melting temperature, high hardness and brittleness. Binder jetting additive manufacturing has been used to fabricate ceramic parts for various applications. This paper presents a literature review on recent advances in ceramic binder jetting. The paper begins with listing applications and material properties investigated in reported studies followed by the effects of raw materials and process parameters on resultant material properties. Raw materials include binder (material, application method, concentration, and saturation) and ceramic feedstock (preparation method, quality metrics, and particle size and shape), and process parameters include layer thickness and postprocessing method. Resultant material properties of interest include density, strength, hardness, and toughness. This review will provide guidance for the selection of raw materials and process parameters to obtain desired material properties for various applications. This paper is concluded by proposing future research directions.

scholarly journals Spreading of Powders in Powder Bed Additive Manufacturing: an Experimental Approach

2021 ◽  
Author(s):  
Valerio Lampitella ◽  
Marco Trofa ◽  
Antonello Astarita ◽  
Gaetano D’Avino
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Experimental Approach ◽  
Physical Mechanism ◽  
Industrial Applications ◽  
Powder Bed Fusion ◽  
Spreading Process ◽  
Powder Bed ◽  
Optimal Window

Powder bed additive manufacturing allows for the production of fully customizable parts and is of great interest for industrial applications. However, the repeatability of the parts and the uniformity of the mechanical properties are still an issue. More specifically, the physical mechanism of the spreading process of the powders, which significantly affects the characteristics of the final part, is not completely understood. In powder bed fusion technologies, the spreading is performed by a device, typically a roller or a blade, that collects the powders from the feedstock and successively deposits them in a layer of several dozens of microns that is then processed with a laser beam. In this work, an experimental approach is developed and employed to study the powder spreading process and analyze in detail the motion of the powders from the accumulation zone to the deposition stage. The presented experiments are carried out on a home-made device that reproduces the spreading process and enables the measurement of the characteristics of the powder bed. Furthermore, the correlation with the process parameters, e.g., the speed of the spreading device, is also investigated. These results can be used to obtain useful insights on the optimal window for the process parameters.

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