Estimating Powder-Polymer Material Properties Used in Design for Metal Fused Filament Fabrication (DfMF3)

Singh, Paramjot; Shaikh, Mohammad Qasim; Balla, Vamsi Krishna; Atre, Sundar V.; Kate, Kunal H.

doi:10.1007/s11837-019-03920-y

Cited by 38 publications

(38 citation statements)

References 41 publications

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“…The feedstock filament development poses processability challenges because of density differences between the constituents, filler dispersion, and rheological behavior. 38 Further, developed composite filaments must be in the desired diameter to be fed into commercially available 3D printers with sufficient flexibility for spooling. 39 These properties allow the filaments to be printed through the printer nozzle without any breakage leading to a block-free layered deposition of prints with dimensional stability.…”

Section: Introductionmentioning

confidence: 99%

Three-Dimensional Printed Lightweight Composite Foams

et al. 2020

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The goal of this paper is to enable three-dimensional (3D) printed lightweight composite foams by blending hollow glass microballoons (GMBs) with high density polyethylene (HDPE). To that end, lightweight feedstock for printing syntactic foam composites is developed. The blend for this is prepared by varying the GMB content (20, 40, and 60 volume %) in HDPE for filament extrusion, which is subsequently used for 3D printing. The rheological properties and the melt flow index (MFI) of blends are investigated for identifying suitable printing parameters. It is observed that the storage and loss modulus, as well as complex viscosity, increase with increasing GMB content, whereas MFI decreases. Further, the coefficient of thermal expansion of HDPE and foam filaments decreases with increasing GMB content, thereby lowering the thermal stresses in prints, which promotes the reduction in warpage. The mechanical properties of filaments are determined by subjecting them to tensile tests, whereas 3D printed samples are tested under tensile and flexure tests. The tensile modulus of the filament increases with increasing GMB content (8–47%) as compared to HDPE and exhibit comparable filament strength. 3D printed foams show a higher specific tensile and flexural modulus as compared to neat HDPE, making them suitable candidate materials for weight-sensitive applications. HDPE having 60% by volume GMB exhibited the highest modulus and is 48.02% higher than the printed HDPE. Finally, the property map reveals a higher modulus and comparable strength against injection- and compression-molded foams. Printed foam registered 1.8 times higher modulus than the molded samples. Hence, 3D printed foams have the potential for replacing components processed through conventional manufacturing processes that have limitations on geometrically complex designs, lead time, and associated costs.

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Section: Introductionmentioning

confidence: 99%

Three-Dimensional Printed Lightweight Composite Foams

et al. 2020

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“…It involves extrusion-based printing with highly filled metal powder-polymer binder filaments, where the polymer binder helps to hold metal particles together in a feedstock and assists in material flow and deposition during printing (Lengauer et al , 2019; Thompson et al , 2019; Wu et al , 2002). As shown in Figure 1, MF 3 involves a filament-based printing process like FFF with additional subsequent steps involving binder removal and sintering at elevated temperatures to densify the printed parts (Singh et al , 2020). It starts with sinterable metal powder, which is Ti-6Al-4V in this study, bonded in a multi-component polymer-based binder forming an optimum composition, like in powder injection molding (Ahn et al , 2009).…”

Section: Introductionmentioning

confidence: 99%

Supportless printing of lattice structures by metal fused filament fabrication (MF³) of Ti-6Al-4V: design and analysis

Shaikh

Graziosi

Atre

2021

RPJ

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Purpose This paper aims to investigate the feasibility of supportless printing of lattice structures by metal fused filament fabrication (MF3) of Ti-6Al-4V. Additionally, an empirical method was presented for the estimation of extrudate deflection in unsupported regions of lattice cells for different geometric configurations. Design/methodology/approach Metal-polymer feedstock with a solids-loading of 59 Vol.% compounded and extruded into a filament was used for three-dimensional printing of lattice structures. A unit cell was used as a starting point, which was then extended to multi-stacked lattice structures. Feasible MF3 processing conditions were identified to fabricate defect-free lattice structures. The effects of lattice geometry parameters on part deflection and relative density were investigated at the unit cell level. Computational simulations were used to predict the part quality and results were verified by experimental printing. Finally, using the identified processing and geometry parameters, multi-stacked lattice structures were successfully printed and sintered. Findings Lattice geometry required considerable changes in MF3 printing parameters as compared to printing bulk parts. Lattice cell dimensions showed a considerable effect on dimensional variations and relative density due to varying aspect ratios. The experimental printing of lattice showed large deflection/sagging in unsupported regions due to gravity, whereas simulation was unable to estimate such deflection. Hence, an analytical model was presented to estimate extrudate deflections and verified with experimental results. Lack of diffusion between beads was observed in the bottom facing surface of unsupported geometry of sintered unit cells as an effect of extrudate sagging in the green part stage. This study proves that MF3 can fabricate fully dense Ti-6Al-4V lattice structures that appear to be a promising candidate for applications where mechanical performance, light-weighting and design customization are required. Originality/value Supportless printing of lattice structures having tiny cross-sectional areas and unsupported geometries is highly challenging for an extrusion-based additive manufacturing (AM) process. This study investigated the AM of Ti-6Al-4V supportless lattice structures using the MF3 process for the first time.

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“…The filaments used in metal-based ME result from the extrusion of feedstock, a mixture of metallic powders combined with a specific concentration of a polymeric binder system, in the correct proportions (usually 60% metallic and 40% polymer feedstocks). The purpose of the mixture, similar to metal hot embossing and metal injection molding (MIM), is to disperse the metal powder in the binder, avoiding internal porosity and agglomeration, which enables a homogeneous biphasic mixture (Sequeiros et al 2020;Singh et al 2019b;Gonzalez-Gutierrez et al 2018b). The powder characteristics influence the filament's rheological behavior in its production and metal ME processes.…”

Section: Introductionmentioning

confidence: 99%

“…Several debinding techniques exist, like solvent debinding, catalytic treatment, thermal treatment, or a combination of two or more (Sequeiros et al 2020). The objective of debinding is to gradually remove the binder materials to keep the manufactured components' shape (Singh et al 2019b). Brown parts, designation after debinding, require a graduate removal of binder to avoid defects (Sequeiros et al 2020;Gonzalez-Gutierrez et al 2018b) and shape loss due to the removal of the binder.…”

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing

Costa

Sequeiros

Vieira

et al. 2021

UPjeng

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Additive manufacturing (AM) is one of the most trending technologies nowadays, and it has the potential to become one of the most disruptive technologies for manufacturing. Academia and industry pay attention to AM because it enables a wide range of new possibilities for design freedom, complex parts production, components, mass personalization, and process improvement. The material extrusion (ME) AM technology for metallic materials is becoming relevant and equivalent to other AM techniques, like laser powder bed fusion. Although ME cannot overpass some limitations, compared with other AM technologies, it enables smaller overall costs and initial investment, more straightforward equipment parametrization, and production flexibility.This study aims to evaluate components produced by ME, or Fused Filament Fabrication (FFF), with different materials: Inconel 625, H13 SAE, and 17-4PH. The microstructure and mechanical characteristics of manufactured parts were evaluated, confirming the process effectiveness and revealing that this is an alternative for metal-based AM.

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Estimating Powder-Polymer Material Properties Used in Design for Metal Fused Filament Fabrication (DfMF3)

Cited by 38 publications

References 41 publications

Three-Dimensional Printed Lightweight Composite Foams

Three-Dimensional Printed Lightweight Composite Foams

Supportless printing of lattice structures by metal fused filament fabrication (MF³) of Ti-6Al-4V: design and analysis

Additive Manufacturing

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Estimating Powder-Polymer Material Properties Used in Design for Metal Fused Filament Fabrication (DfMF3)

Cited by 38 publications

References 41 publications

Three-Dimensional Printed Lightweight Composite Foams

Three-Dimensional Printed Lightweight Composite Foams

Supportless printing of lattice structures by metal fused filament fabrication (MF3) of Ti-6Al-4V: design and analysis

Additive Manufacturing

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Product

Resources

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Supportless printing of lattice structures by metal fused filament fabrication (MF³) of Ti-6Al-4V: design and analysis