A novel printable high-speed steel filament: Towards the solution for wear-resistant customized tools by AM alternative

Naranjo, Jesús Andrés; Berges, Cristina; Gallego, Alberto; Herranz, Gemma

doi:10.1016/j.jmrt.2021.02.001

Cited by 16 publications

(8 citation statements)

References 21 publications

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“…The material with a liquid-like consistency is pushed through a die and then selectively deposited, layer-by-layer, to shape a threedimensional object [15]. MEX allows the production of complex-shaped parts not only from thermoplastics [20], fiber-filled composites [21], and low melting point (~450 • C) metallic alloys [22], but also from high-melting-point (>1000 • C) metallic alloys [15,[23][24][25][26][27][28][29][30], such as copper [31], ceramics [15,[32][33][34][35][36][37][38][39], and hard metals and cermets [40][41][42]. Highly-filled thermoplastic filaments are used as the feedstock material to obtain metallic, ceramic and cermet parts.…”

Section: Introductionmentioning

confidence: 99%

“…The main disadvantage of using filaments as feedstock is that binder systems must be adjusted to have enough mechanical strength and flexibility so the filament can be reliably processed in standard commercial MEX machines. Nevertheless, new binders are available, and filaments with copper and other sinterable powders have been reported in the literature [15,29,31,32,39,49,[51][52][53][54][55][56][57][58][59][60][61][62][63][64]. Therefore, due to the increasing popularity of filamentbased MEX, this technique was selected for shaping copper specimens in this study.…”

Section: Introductionmentioning

confidence: 99%

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Bending Properties of Lightweight Copper Specimens with Different Infill Patterns Produced by Material Extrusion Additive Manufacturing, Solvent Debinding and Sintering

González-Gutiérrez

Cano

Ecker³

et al. 2021

Applied Sciences

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Material extrusion additive manufacturing (MEX) is a versatile technology for producing complex specimens of polymers, ceramics and metals. Highly-filled filaments composed of a binder system and a high-volume content of sinterable powders are needed to produce ceramic or metal parts. After shaping the parts via MEX, the binder is removed and the specimens are sintered to obtain a dense part of the sintered filler particles. In this article, the applicability of this additive manufacturing process to produce copper specimens is demonstrated. The particular emphasis is on investigating the production of lightweight specimens that retain mechanical properties without increasing their weight. The effect of infill grades and the cover presence on the debinding process and the flexural properties of the sintered parts was studied. It was observed that covers could provide the same flexural strength with a maximum weight reduction of approximately 23%. However, a cover on specimens with less than 100% infill significantly slows down the debinding process. The results demonstrate the applicability of MEX to produce lightweight copper specimens.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Bending Properties of Lightweight Copper Specimens with Different Infill Patterns Produced by Material Extrusion Additive Manufacturing, Solvent Debinding and Sintering

González-Gutiérrez

Cano

Ecker³

et al. 2021

Applied Sciences

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show abstract

“…However, the filament feedstock requires high flexibility so that it can be easily spooled, handled and printed. To achieve this characteristic, the binder must be highly elastic, such as the thermoplastic elastomer, TPE, which is usually employed in the in-house built filament feedstock [31,32,39,50,52,96,102,106], as presented in Table 3. The usage of high flexibility polymer as a part of the binder system, such as PA [29], PLA [51,89] and PO [37,96,102,168] can also be helpful.…”

Section: Feedstockmentioning

confidence: 99%

“…To achieve this characteristic, the binder must be highly elastic, such as the thermoplastic elastomer, TPE, which is usually employed in the in-house built filament feedstock [31,32,39,50,52,96,102,106], as presented in Table 3. The usage of high flexibility polymer as a part of the binder system, such as PA [29], PLA [51,89] and PO [37,96,102,168] can also be helpful. Otherwise, special features, such as a heating chamber, are required to reduce the brittleness of the filament during feeding [56,64].…”

Section: Feedstockmentioning

confidence: 99%

A Review on Material Extrusion Additive Manufacturing of Metal and How It Compares with Metal Injection Moulding

Suwanpreecha¹,

Manonukul²

2022

Metals

107

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Material extrusion additive manufacturing of metal (metal MEX), which is one of the 3D printing processes, has gained more interests because of its simplicity and economics. Metal MEX process is similar to the conventional metal injection moulding (MIM) process, consisting of feedstock preparation of metal powder and polymer binders, layer-by-layer 3D printing (metal MEX) or injection (MIM) to create green parts, debinding to remove the binders and sintering to create the consolidated metallic parts. Due to the recent rapid development of metal MEX, it is important to review current research work on this topic to further understand the critical process parameters and the related physical and mechanical properties of metal MEX parts relevant to further studies and real applications. In this review, the available literature is systematically summarised and concluded in terms of feedstock, printing, debinding and sintering. The processing-related physical and mechanical properties, i.e., solid loading vs. dimensional shrinkage maps, sintering temperature vs. relative sintered density maps, stress vs. elongation maps for the three main alloys (316L stainless steel, 17-4PH stainless steel and Ti-6Al-4V), are also discussed and compared with well-established MIM properties and MIM international standards to assess the current stage of metal MEX development.

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“…This method is adopted for powder metallurgical manufacturing by using the same thermoplastic filaments but filling them with ceramic, metal or glass particles prior to AM deposition [7][8][9][10]. This approach to additively shape ceramic and metal materials has been used since the 1990s and has experienced a significant increase in popularity in recent years [11][12][13][14][15][16][17].…”

Section: Introductionmentioning

confidence: 99%

Fused Filament Fabrication of NiTi Components and Hybridization with Laser Powder Bed Fusion for Filigree Structures

et al. 2021

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The present study introduces an approach to the powder metallurgical shaping of a pseudo-elastic nickel–titanium (NiTi 44 alloy) combining two different additive manufacturing (AM) processes, namely fused filament fabrication (FFF) and laser powder bed fusion (LPBF), by manufacturing filigree structures on top of sintered FFF parts. Both processes start with commercial gas atomized NiTi powder, which is fractionated into two classes. Using the fine fraction with particle sizes <15 µm, robust thermoplastic filaments based on a non-commercial binder system were produced and processed to different auxetic and non-auxetic geometries employing a commercial standard printer. FTIR analysis for thermal decomposition products was used to develop a debinding regime. After sintering, the phase transformation austenite/martensite was characterized by DSC in as sintered and annealed state. Precipitates resulting from residual impurities were detected by micrographs and XRD. They led to an increased transformation temperature. Adjusting the oxygen and carbon content in the alloy remains a challenging issue for powder metallurgical processed NiTi alloys. Filigree lattice structures were built onto the surfaces of the sintered FFF parts by LPBF using the coarser powder fraction (15–45 µm). A good material bond was formed, resulting in the first known NiTi hybrid, which introduces new production and design options for future applications.

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A novel printable high-speed steel filament: Towards the solution for wear-resistant customized tools by AM alternative

Cited by 16 publications

References 21 publications

Bending Properties of Lightweight Copper Specimens with Different Infill Patterns Produced by Material Extrusion Additive Manufacturing, Solvent Debinding and Sintering

Bending Properties of Lightweight Copper Specimens with Different Infill Patterns Produced by Material Extrusion Additive Manufacturing, Solvent Debinding and Sintering

A Review on Material Extrusion Additive Manufacturing of Metal and How It Compares with Metal Injection Moulding

Fused Filament Fabrication of NiTi Components and Hybridization with Laser Powder Bed Fusion for Filigree Structures

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