Numerical simulation and experimental measurement of pressureless sintering of stainless steel part printed by Binder Jetting Additive Manufacturing

Compensation of sintering deformation for components manufactured by metal binder jetting using numerical simulations

“…The qualified SOVS material model for MBJ presented in the research by Sadeghi Borujeni et al (2022) is used in the current paper to predict sintering deformations. However, the manufacturing elements used to fabricate the specimens in the current study differ in printer, powder size distribution (PSD), printing layer thickness and sintering cycle from those in the research by Sadeghi Borujeni et al Nevertheless, some of material parameters including apparent, bulk and shear viscosity, as well as grain size are mainly affected by temperature, initial grain size, relative density and diffusion coefficients and not dependent on the reported differences (Olevsky, 1998; Riedel and Blug, 2002; Zhang et al , 2021). Therefore, those material parameters are borrowed from Sadeghi Borujeni et al However, densification behavior depends directly on PSD (Mostafaei et al , 2019; Chen et al , 2021), printing layer thickness (Barthel et al , 2021) and sintering cycle (Mostafaei et al , 2016; Huber et al , 2021).…”

“…For this purpose, a phenomenological model of viscous sintering, originally introduced by Skorokhod et al (1993) and Olevsky (1998) for powder metallurgy applications can be implemented in the framework of the FE method. Recently, Zhang et al (2021) implemented the Skorokhod and Olevsky viscous sintering (SOVS) model for MBJ components and showed an acceptable prediction accuracy. In a study by Sadeghi Borujeni et al (2022), the SOVS model has been inclusively qualified and calibrated for MBJ technology.…”

A reactive molecular dynamics study of bi-modal particle size distribution in binder-jetting additive manufacturing using stainless-steel powders

“…As the process works at room temperature, there is no need for thermal conductivity considerations. 8 Finally, binder-jetted parts can be fabricated without support structures, as overhanging parts are supported by the surrounding loose powders. In addition, multiple parts can be stacked on top of each other without supports which increase production rate.…”

Binder Jetting Additive Manufacturing: Spreading and Permeation of Multiple Micron Droplets in Porous Media

“…To investigate the densification and deformation behavior of BJAM printed green parts during the pressureless sintering process, Zhang et al. [ 10 ] developed a finite element model containing elastic‐viscoplastic constitutive equations for calculating uniaxial equivalent creep strain and volume expansion strain, and further utilized to evaluate two methods for calculating uniaxial equivalent creep strain, one based on viscosity and the other on power‐law based creep. Ziaee et al.…”

“…Panagiotis Stavropoulos et al [9] presented a metamodeling framework for AM, aiming to increase the practicality of simulations that investigate the effect of the movement of the head on part quality, and the utilized spectrum of AM processes is discussed with respect to the modelling types, namely theoretical/computational and experimental/empirical. To investigate the densification and deformation behavior of BJAM printed green parts during the pressureless sintering process, Zhang et al [10] developed a finite element model containing elastic-viscoplastic constitutive equations for calculating uniaxial equivalent creep strain and volume expansion strain, and further utilized to evaluate two methods for calculating uniaxial equivalent creep strain, one based on viscosity and the other on power-law based creep. Ziaee et al [11] proposed that binder jetting (BJ) can be applied to almost any powder with high productivity, and the BJ process utilizes a wide range of technologies, including printing techniques, powder deposition, dynamic binder/powder interactions, and post-processing methods.…”