Numerical simulation of shrinkage and deformation during sintering in metal binder jetting with experimental validation

Borujeni, Shahrooz Sadeghi; Shad, Anwar; Venkata, Kiranmayi Abburi; Günther, Nico; Ploshikhin, Vasily

doi:10.1016/j.matdes.2022.110490

Cited by 25 publications

(9 citation statements)

References 38 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Even the specimens with low absolute GRD deviations, do not ensure a precise dimensional accuracy. This is however in line with the implemented material model, which does not consider anisotropic properties of green parts due to the interlayer gaps in the build direction existing in MBJ (Sadeghi Borujeni et al, 2022).…”

Section: Sintered Specimenssupporting

confidence: 72%

“…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).…”

Section: Methodsmentioning

confidence: 99%

“…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. Using a bracket model, the ability of the introduced model for nonlinear deformations has been proven.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

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

Borujeni

Saluja²,

Ploshikhin³

2022

RPJ

View full text Add to dashboard Cite

Purpose This study aims at compensating for sintering deformation of components manufactured by metal binder jetting (MBJ) technology. Design/methodology/approach In the present research, numerical simulations are used to predict sintering deformation. Subsequently, an algorithm is developed to counteract the deformations, and the compensated deformations are morphed into a CAD model for printing. Several test cases are designed, compensated and manufactured to evaluate the accuracy of the compensation calculations. A consistent accuracy measurement method is developed for both green and sintered parts. The final sintered parts are compared with the desired final shape, and the accuracy of the model is discussed. Furthermore, the effect of initial assumptions in the calculations, including green part densities, and green part dimensions on the final dimensional accuracy are studied. Findings The proposed computational framework can compensate for the sintering deformations with acceptable accuracy, especially in the directions, for which the used material model has been calibrated. The precise assumption of green part density values is important for the accuracy of compensation calculations. For achieving tighter dimensional accuracy, green part dimensions should be incorporated into the computational framework. Originality/value Several studies have already predicted sintering deformations using numerical methods for MBJ parts. However, very little research has been dedicated to the compensation of sintering deformations with numerical simulations, and to the best of the best of the authors' knowledge, no previous work has studied the effect of green part properties on dimensional accuracy of compensation calculations. This paper introduces a method to omit or minimize the trial-and-error experiments and leads to the manufacturing of dimensionally accurate geometries.

show abstract

Section: Sintered Specimenssupporting

confidence: 72%

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

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

Borujeni

Saluja²,

Ploshikhin³

2022

RPJ

View full text Add to dashboard Cite

show abstract

“…The model can capture the empirical trend of cylindricity form error and shrinkage at different inclination of hole axis, however some discrepancies have been observed for smallest holes (3 mm diameter), when hole axis is perpendicular to the building direction. The marked underestimation of the experimental results has been ascribed to the combined effect of viscous-plastic material behavior and gravity load, on the basis of previous experimental work on shape deformation of overhanging structure and cantilever beams [23][24][25]. It was supposed that the mass of powder above hole section might have determined an extra deformation of hole section, on the reason of viscous-plastic material behavior.…”

Section: Introductionmentioning

confidence: 99%

Influence of shape distortion on the precision of holes in parts fabricated by metal binder jetting

Zago

Lecis

Mariani

et al. 2023

Int J Interact Des Manuf

View full text Add to dashboard Cite

Metal binder jetting (MBJ) is an additive manufacturing (AM) technology split into two process steps: printing and sintering. Firstly, product is built up layer-by-layer by the selective deposition of a binder agent on a powder bed. Secondly, a thermal treatment (sintering) consolidates the metal structure. MBJ is currently becoming more and more attractive on the reason of high potential scalability, cost-effective production and wide range of available material feedstocks. However, the transition towards industrial scale production is restrained by the critical control of dimensional and geometrical precision of parts after sintering operation. In fact, product geometry is affected by anisotropic dimensional change or even shape distortion. This study aims at investigating the dimensional and geometrical precision of through holes. Three sample geometries were designed, having a through hole with axis perpendicular to the building direction and located at different levels along sample height. Samples were measured by a coordinate measuring machine before and after sintering, in order to assess the shrinkage and any shape change. Results highlight the inhomogeneous volumetric and linear shrinkage of the three geometries, which is influenced by the printing position in the building plane. A macroscopic deformation of parallelepiped geometry was also evidenced, caused by the superposition of layer shifting originated on printing, and by the frictional forces between sample surface and alumina support during sintering. Such distortion significantly affects the shrinkage and form error of holes.

show abstract

“…Additionally, unlike traditional PM parts which are pressed to almost 80% relative density before sintering [ 17 , 18 ], BJAM green parts typically have a much lower green part density, typically ranging between 45 and 65% [ 19 ], and thus densification from this state usually results in remnant porosity and a significant distortion of design geometry. Prior research has shown that green densities in the range ∼50% are easily obtainable with WA steel powders [ 3 , 9 ].…”

Section: Introductionmentioning

confidence: 99%

Supersolidus liquid phase sintering of water-atomized low-alloy steel in binder jetting additive manufacturing

Yang

Keshavarz

Vlasea

et al. 2023

Heliyon

View full text Add to dashboard Cite

Numerical simulation of shrinkage and deformation during sintering in metal binder jetting with experimental validation

Cited by 25 publications

References 38 publications

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

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

Influence of shape distortion on the precision of holes in parts fabricated by metal binder jetting

Supersolidus liquid phase sintering of water-atomized low-alloy steel in binder jetting additive manufacturing

Contact Info

Product

Resources

About