Optimization of composite extrusion modeling process parameters for 3D printing of low-alloy steel AISI 8740 using metal injection moulding feedstock

Riaz, Abdullah; Töllner, Philip; Ahrend, Alexander; Springer, Armin; Milkereit, Benjamin; Seitz, Hermann

doi:10.1016/j.matdes.2022.110814

Cited by 31 publications

(4 citation statements)

References 35 publications

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“…To form ceramic parts with high mechanical properties, the green part first needs to go through the de-binding process. De-binding refers to the removal of parts other than the solid content in the ceramic slurry system by a thermal de-binding − or solvent de-binding method. , De-binding of the green part is the longest time-consuming step in the process of additive manufacturing via the light-curing method of ceramic materials, and various defects such as cracking, delamination, deformation, and collapse easily appear in this process, which affects the integrity of products and reduces the mechanical properties of materials. Therefore, the de-binding process is the key step in the forming process of SiO 2 ceramic products.…”

Section: Resultsmentioning

confidence: 99%

Research on Rheology and Formability of SiO₂ Ceramic Slurry Based on Additive Manufacturing Technology via a Light Curing Method

Fang

Yan

2022

ACS Omega

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SiO 2 ceramic parts with complex structures were formed by additive manufacturing technology via a light curing method combined with a heat treatment process. To reveal the influence mechanism of rheology and formability of SiO 2 ceramic slurry, the microstructure, morphology, and properties of light-cured SiO 2 ceramic samples were characterized by a viscosity test, thermogravimetric analysis (TG-DTG), X-ray diffraction (XRD), a scanning electron microscope (SEM), and a series of tests for physical properties (bending strength, mass burning rate, and densification). The results indicate that the main effect of the dispersant-type factor was more significant than the pH value. When the dispersant was ammonium polyacrylate (PMAA-NH 4 ) with a content of 1.0 wt % and the pH value of the slurry system was 9, the viscosity of SiO 2 ceramic slurry could be controlled to the lowest. It was also found that the sintering temperature in the experiment had no effect on the crystalline phase of SiO 2 ceramics. When the sintering temperature was 1250 °C and the solid content was 65 vol %, the micromorphology of the samples was uniform. Under this condition, the bending strength of the sample reached 14.9 MPa and the densification was 76.43%.

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Section: Resultsmentioning

confidence: 99%

Research on Rheology and Formability of SiO₂ Ceramic Slurry Based on Additive Manufacturing Technology via a Light Curing Method

Fang

Yan

2022

ACS Omega

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“…The formation of interlayer lines introduces pores into the parts, which can impact the densities and mechanical properties of the sintered parts. The interlayer bonding effect can be modified by adjusting the printing parameters, thereby changing the mechanical properties of the parts [23,29,46]. The 0.6 mm diameter nozzle often clogged and could not print normally.…”

Section: Feedstock Characterization and 3d Printingmentioning

confidence: 99%

Printing, Debinding and Sintering of 15-5PH Stainless Steel Components by Fused Deposition Modeling Additive Manufacturing

Chang,

Zhang,

et al. 2023

Materials

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Metal FDM technology overcomes the problems of high cost, high energy consumption and high material requirements of traditional metal additive manufacturing by combining FDM and powder metallurgy and realizes the low-cost manufacturing of complex metal parts. In this work, 15-5PH stainless steel granules with a powder content of 90% and suitable for metal FDM were developed. The flowability and formability of the feedstock were investigated and the parts were printed. A two-step (solvent and thermal) debinding process is used to remove the binder from the green part. After being kept at 75 °C in cyclohexane for 24 h, the solvent debinding rate reached 98.7%. Following thermal debinding, the material’s weight decreased by slightly more than 10%. Sintering was conducted at 1300 °C, 1375 °C and 1390 °C in a hydrogen atmosphere. The results show that the shrinkage of the sintered components in the X-Y-Z direction remains quite consistent, with values ranging from 13.26% to 19.58% between 1300 °C and 1390 °C. After sintering at 1390 °C, the material exhibited a relative density of 95.83%, a hardness of 101.63 HRBW and a remarkable tensile strength of 770 MPa. This work realizes the production of metal parts using 15-5PH granules’ extrusion additive manufacturing, providing a method for the low-cost preparation of metal parts. And it provides a useful reference for the debinding and sintering process settings of metal FDM. In addition, it also enriches the selection range of materials for metal FDM.

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“…Nevertheless, an excessively high nozzle temperature has an undesirable effect on dimensional accuracy due to overflow and slow solidification [60]. Correspondingly, polymer degradation can occur if the temperature is too high resulting in reduced mechanical properties [68]. Feedstock F2_ST was 3D printed with a nozzle temperature set between 170 and 210 °C.…”

Section: Mechanical Properties Of Binders and Feedstocksmentioning

confidence: 99%

Influence of Binder Composition and Material Extrusion (MEX) Parameters on the 3D Printing of Highly Filled Copper Feedstocks

et al. 2022

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This work aims to better understand the type of thermoplastic binders required to produce highly loaded copper filaments that can be successfully printed via low-cost filament-based material extrusion (MEX). Compounding feedstock material with 55 vol.% of copper and three multi-component binder systems has been performed. The MEX behavior of these feedstocks was evaluated by depositing material at different speeds and appropriately selecting the extrusion temperature depending on the binder composition. The rest of the MEX parameters remained constant to evaluate the printing quality for the different feedstocks. Printable filaments were produced with low ovality and good surface quality. The filaments showed good dispersion of the powder and polymeric binder system in SEM analysis. The feedstock mechanical properties, i.e., the tensile strength of the filament, were sufficient to ensure proper feeding in the MEX machine. The viscosity of the feedstock systems at the adjusted printing temperatures lies in the range of 102–103 Pa·s at the shear rate of 100–1000 s−1, which appears to be sufficient to guarantee the correct flowability and continuous extrusion. The tensile properties vary greatly (e.g., ultimate tensile strength 3–9.8 MPa, elongation at break 1.5–40.5%), and the most fragile filament could not be reliably printed at higher speeds. Micrographs of the cross-section of printed parts revealed that as the printing speed increased, the porosity was minimized because the volumetric flow of the feedstock material increased, which can help to fill pores. This study offers new insights into the feedstock requirements needed to produce low-cost intricate copper components of high quality in a reliable and efficient manner. Such components can find many applications in the electronics, biomedical, and many other industries.

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Optimization of composite extrusion modeling process parameters for 3D printing of low-alloy steel AISI 8740 using metal injection moulding feedstock

Cited by 31 publications

References 35 publications

Research on Rheology and Formability of SiO₂ Ceramic Slurry Based on Additive Manufacturing Technology via a Light Curing Method

Research on Rheology and Formability of SiO₂ Ceramic Slurry Based on Additive Manufacturing Technology via a Light Curing Method

Printing, Debinding and Sintering of 15-5PH Stainless Steel Components by Fused Deposition Modeling Additive Manufacturing

Influence of Binder Composition and Material Extrusion (MEX) Parameters on the 3D Printing of Highly Filled Copper Feedstocks

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Optimization of composite extrusion modeling process parameters for 3D printing of low-alloy steel AISI 8740 using metal injection moulding feedstock

Cited by 31 publications

References 35 publications

Research on Rheology and Formability of SiO2 Ceramic Slurry Based on Additive Manufacturing Technology via a Light Curing Method

Research on Rheology and Formability of SiO2 Ceramic Slurry Based on Additive Manufacturing Technology via a Light Curing Method

Printing, Debinding and Sintering of 15-5PH Stainless Steel Components by Fused Deposition Modeling Additive Manufacturing

Influence of Binder Composition and Material Extrusion (MEX) Parameters on the 3D Printing of Highly Filled Copper Feedstocks

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Product

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Research on Rheology and Formability of SiO₂ Ceramic Slurry Based on Additive Manufacturing Technology via a Light Curing Method

Research on Rheology and Formability of SiO₂ Ceramic Slurry Based on Additive Manufacturing Technology via a Light Curing Method