Feasibility study of producing multi-metal parts by Fused Filament Fabrication (FFF) technique

Mousapour, Mehrdad; Salmi, Mika; Klemettinen, Lassi; Partanen, Jouni

doi:10.1016/j.jmapro.2021.05.021

Cited by 58 publications

(18 citation statements)

References 22 publications

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“…From Table 1, it is worth reinforcing that the filament-based system is the most popular type with various printer models being utilised for this system. These filament-based printers can be classified into three groups, which are (1) in-house built printers, (2) general polymer FDM [4]), showing polymer skin surrounding mixing of polymer and metal powder, (b) 316L metal filament by Virtual foundry (adapted from [72]) and (c) 17-4PH stainless steel filament for MetalX system by Markforged, Inc. (Reprinted with permission from ref. [8].…”

Section: Printermentioning

confidence: 99%

“…Similar to MIM, the most important factor influencing shape formation is the binder. Feedstock with water-soluble binder [68] requires lower printing temperature than those with solvent and/or thermal debinding, e.g., TPE and PO [49,52,54], PA [29], POM [9,53,56,57,66,70], PLA [72] or PE [75,81] based binders. The printing bed is heated in the range of 40 to 100 • C to increase the adhesion and reduce warping defects generated by the shrinkage during solidification [77,173].…”

Section: Printingmentioning

confidence: 99%

“…The higher sintering temperature and longer sintering time provide the highest relative sintered density [149]. The effect of sintering conditions on the relative sintered density of 17-4PH [8,49,64,92,110], 316L [9,41,45,52,53,56,57,66,68,70,72,75,81,98,108] and Ti-6Al-4V [78,79] alloys fabricated by metal MEX, MIM [134,157,[159][160][161]163,164,170,171] and the corresponding MIM international standards [169,172] are graphically compared in Figures 19-21, respectively. Figure 19 shows that most relative sintered densities of MEX 17-4PH alloy, which are in the range of 97% to 99%, meet the minimum value of the MPIF standard 35 for MIM materials (>96.7%).…”

Section: Effects Of Sintering Conditions On the Relative Sintered Den...mentioning

confidence: 99%

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

Suwanpreecha¹,

Manonukul²

2022

Metals

113

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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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Section: Printermentioning

confidence: 99%

Section: Printingmentioning

confidence: 99%

Section: Effects Of Sintering Conditions On the Relative Sintered Den...mentioning

confidence: 99%

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

Suwanpreecha¹,

Manonukul²

2022

Metals

113

View full text Add to dashboard Cite

show abstract

“…[8]. Three dimensional printing technologies also have some possibilities of using composite materials [9,10], especially technologies such as Selective Laser Sintering-SLS, Fused Filament Fabrication-FFF, also commercially known as Fused Deposition Modeling-FDM ® [11].…”

Section: Introductionmentioning

confidence: 99%

Comparative Analysis of Polymer Composites Produced by FFF and PJM 3D Printing and Electrospinning Technologies for Possible Filter Applications

et al. 2022

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Three-dimensional printing technologies are mainly used to build objects with complex shapes and geometry, largely prototypes, and thanks to the possibility of building very thin layers of material with small pores, electrospinning technology allows for the creation of structures with filtration properties, in particular very small particles. The combination of these technologies creates new possibilities for building complex-shape composites that have not been comprehensively tested so far. The article describes the results of research on composites manufactured by combining samples prepared with two 3D printing technologies, Fused Filament Fabrication (FFF) and Photo-Curing of Liquid Polymer Resins (PJM) in combination with electrospinning (ES) technology. The surface morphology of composites manufactured from biocompatible materials was investigated using Confocal Laser Scanning Microscopy (CLSM) and contact angle measurements, and chemical composition analysis was studied using Fourier transform infrared spectroscopy (FTIR). This approach to creating composites appears to be an alternative to developing research for filtration applications. The article presents basic research illustrating the quality of composites produced by combining two unconventional technologies: 3D printing and electrospinning (ES). The analysis of the research results showed clear differences in the structure of composites produced with the use of various 3D printing technologies. The CLSM analysis showed a much better orientation of the fibers in the MED610 + PAN/gelatin composite, and the measurement of the contact angle and its indirect interpretation also for this composite allows for the conclusion that it will be characterized by a higher value of adhesion force. Moreover, such composites could be used in the future for the construction of filtering devices and in medical applications.

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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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Feasibility study of producing multi-metal parts by Fused Filament Fabrication (FFF) technique

Cited by 58 publications

References 22 publications

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

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

Comparative Analysis of Polymer Composites Produced by FFF and PJM 3D Printing and Electrospinning Technologies for Possible Filter Applications

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

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