A study of parameter and post-processing effects on surface quality improvement of Binder Jet 3D-printed Invar36 alloy parts

Lores, A.; Azurmendi, N.; Agote, I.; Espinosa, Elixabete; García-Blanco, María Belén

doi:10.1007/s40964-022-00267-w

Cited by 9 publications

(3 citation statements)

References 58 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The Taguchi method was preferred in this study because effective results can be obtained quickly and cheaply. Many studies use the Taguchi method in binder jetting, other additive manufacturing methods and other engineering fields (Cai et al , 2023; Javidi et al , 2023; Lores et al , 2022; Modi and Sahu, 2021; Ni et al , 2023; Pulipaka et al , 2023; Sahu and Modi, 2022).…”

Section: Methodsmentioning

confidence: 99%

Effective use of adaptive slicing in binder jetting using Taguchi method and surface roughness measurement with image processing

Baş,

Yapıcı,

Ergün

2024

RPJ

View full text Add to dashboard Cite

Purpose The use of additive manufacturing in many branches of industry is increasing significantly because of its many advantages, such as being able to produce complex parts that cannot be produced by classical methods, using fewer materials, easing the supply chain with on-site production, being able to produce with all kinds of materials and producing lighter parts. The binder jetting technique, one of the additive manufacturing methods researched within the scope of this work, is predicted to be the additive manufacturing method that will grow the most in the next decade, according to many economic reports. Although additive manufacturing methods have many advantages, they can be slower than classical manufacturing methods regarding production speed. For this reason, this study aims to increase the manufacturing speed in the binder jetting method. Design/methodology/approach Adaptive slicing and variable binder amount algorithm (VBAA) were used to increase manufacturing speed in binder jetting. Taguchi method was used to optimize the layer thickness and saturation ratio in VBAA. According to the Taguchi experimental design, 27 samples were produced in nine different conditions, three replicates each. The width of the samples in their raw form was measured. Afterward, the samples were sintered at 1,500 °C for 2 h. After sintering, surface roughness and density tests were performed. Therefore, the methods used have been proven to be successful. In addition, measurement possibilities with image processing were investigated to make surface roughness measurements more accessible and more economical. Findings As a result of the tests, the optimum printing condition was decided to be 180–250 µm for layer thickness and 50% for saturation. A separate test sample was then designed to implement adaptive slicing. This test sample was produced in three pieces: adaptive (180–250 µm), thin layer (180 µm) and thick layer (250 µm) with the determined parameters. The roughness values of the adaptive sliced sample and the thin layer sample were similar and better than the thick layer sample. A similar result was obtained using 12.31% fewer layers in the adaptive sample than in the thin layer sample. Originality/value The use of adaptive slicing in binder jetting has become more efficient. In this way, it will increase the use of adaptive slicing in binder jetting. In addition, a cheap and straightforward image processing method has been developed to calculate the surface roughness of the parts.

show abstract

Section: Methodsmentioning

confidence: 99%

Effective use of adaptive slicing in binder jetting using Taguchi method and surface roughness measurement with image processing

Baş,

Yapıcı,

Ergün

2024

RPJ

View full text Add to dashboard Cite

show abstract

“…In binder jet printing, the gradual buildup of defects between layers often results from inaccurately chosen process parameters. Researchers have dedicated significant efforts to address and mitigate these issues [87][88][89]. In this study, various types of multilayer defects observed are illustrated in Figure 8.…”

Section: Multilayer Accumulation Defectsmentioning

confidence: 99%

Enhancing Quality Control: Image-Based Quantification of Carbides and Defect Remediation in Binder Jetting Additive Manufacturing

Choudhari,

Elder,

Mugale

et al. 2024

Materials

View full text Add to dashboard Cite

While binder jetting (BJ) additive manufacturing (AM) holds considerable promise for industrial applications, defects often compromise part quality. This study addresses these challenges by investigating binding mechanisms and analyzing common defects, proposing tailored solutions to mitigate them. Emphasizing defect identification for effective quality control in BJ-AM, this research offers strategies for in-process rectification and post-process evaluation to elevate part quality. It shows how to successfully process metallic parts with complex geometries while maintaining consistent material properties. Furthermore, the paper explores the microstructure of AISI M2 tool steel, utilizing advanced image processing techniques like digital image analysis and SEM images to evaluate carbide distribution. The results show that M2 tool steel has a high proportion of M6C carbides, with furnace-cooled samples ranging from ~2.4% to 7.1% and MC carbides from ~0.4% to 9.4%. M6C carbides ranged from ~2.6% to 3.8% in air-cooled samples, while water-cooled samples peaked at ~8.52%. Sintering conditions also affected shrinkage, with furnace-cooled samples showing the lowest rates (1.7 ± 0.4% to 5 ± 0.4%) and water-cooled samples showing the highest (2 ± 0.4% to 14.1 ± 0.4%). The study recommends real-time defect detection systems with autonomous corrective capabilities to improve the quality and performance of BJ-AM components.

show abstract

“…Because it has a similar coefficient of thermal expansion to composite materials, it is also used in areas where composite materials are present (Zhan et al , 2016). It is also used in many fields such as storage and transportation of liquefied natural gas (Xu et al , 2019), new Jammes Webb space telescope backplane fittings and interfaces (Lores et al , 2022), metrological instruments, optical devices, advanced composite molds for aerospace industry, temperature regulators, commercial laser interferometers, radar and microwave cavity resonators and special electronic enclosures (Khanna et al , 2018). Surface quality is an important parameter in such critical applications (Ulutan ve Ozel, 2011).…”

Section: Introductionmentioning

confidence: 99%

Investigation of the wear behavior of FeNi36 alloy cut by WEDM method under different loads

Ceritbinmez,

Kanca,

Tuna

et al. 2023

AEAT

View full text Add to dashboard Cite

Purpose FeNi36 (Invar-36) alloy is widely used in the fabrication of molding tools in aerospace industries but there remains a need to improve its wear and friction performance due to its relatively low hardness. The formation of a heat affected zone (HAZ) on the surface of Invar-36 cut by wire electric discharge machining (WEDM) is promising to enhance its tribological properties. This study aims to investigate the tribological performance of WEDM-treated Invar-36 via a ball-on-disk tribometer in dry-sliding conditions. Design/methodology/approach The untreated and WEDM-treated Invar-36 surfaces were reciprocated against an alumina ball at a sliding velocity of 40 mm/s, a stroke length of 10 mm and a sliding duration of 125 min under loads of 5, 10 and 20 N. The worn surfaces were characterized using a 2D profilometry and a scanning electron microscope equipped with energy-dispersive spectroscopy. Findings The results showed that the WEDM-treated surface had a superior friction coefficient and wear resistance in comparison to the untreated surface, due to the grown HAZ. There was found to be a 9.3%–11.4% decrease in the friction coefficient and a 47%–57% reduction in the wear volume after the WEDM treatment. Both the untreated and WEDM-treated Invar-36 surfaces found abrasion and plastic deformation as the dominant wear mechanisms. Originality/value Previous works have not focused on the tribological performance of the WEDM-treated Invar-36 extensively used for molding tools in aerospace industries. Our findings provide compelling evidence that the WEDM treatment improved the wear and friction performance of Invar-36 alloy because of the grown HAZ.

show abstract

A study of parameter and post-processing effects on surface quality improvement of Binder Jet 3D-printed Invar36 alloy parts

Abstract: Metadata of the article that will be visualized in OnlineFirst ArticleTitleA study of parameter and post-processing effects on surface quality improvement of Binder Jet 3D-printed Invar36 alloy parts

Cited by 9 publications

References 58 publications

Effective use of adaptive slicing in binder jetting using Taguchi method and surface roughness measurement with image processing

Effective use of adaptive slicing in binder jetting using Taguchi method and surface roughness measurement with image processing

Enhancing Quality Control: Image-Based Quantification of Carbides and Defect Remediation in Binder Jetting Additive Manufacturing

Investigation of the wear behavior of FeNi36 alloy cut by WEDM method under different loads

Contact Info

Product

Resources

About