Additive manufacturing (AM), also known as 3D printing or rapid prototyping, is gaining increasing attention due to its ability to produce parts with added functionality and increased complexities in geometrical design, on top of the fact that it is theoretically possible to produce any shape without limitations. However, most of the research on additive manufacturing techniques are focused on the development of materials/process parameters/products design with different additive manufacturing processes such as selective laser melting, electron beam melting, or binder jetting. However, we do not have any guidelines that discuss the selection of the most suitable additive manufacturing process, depending on the material to be processed, the complexity of the parts to be produced, or the design considerations. Considering the very fact that no reports deal with this process selection, the present manuscript aims to discuss the different selection criteria that are to be considered, in order to select the best AM process (binder jetting/selective laser melting/electron beam melting) for fabricating a specific component with a defined set of material properties.

Additive Manufacturing Processes: Selective Laser Melting, Electron Beam Melting and Binder Jetting-Selection Guidelines.

Binder jet 3D printing—Process parameters, materials, properties, modeling, and challenges

This paper investigates the effect of temperature on the microstructure, failure mechanism and compressive mechanical properties of newly developed ZA27 syntactic foams. Two different types of filler particles are considered, i.e. expanded perlite (P) and expanded glass (G). Metallic syntactic foam (MSF) has been produced via a counter-gravity infiltration process of packed particle beds, followed by controlled thermal exposure. Quasi-static compressive tests were carried out on cylindrical samples at five different in-situ testing temperatures between 25 °C and 350 °C. At all considered temperatures, P-MSF exhibits superior mechanical properties compared to G-MSF. The mechanical properties of both foam types decrease significantly with increasing testing temperature. For comparison, solid ZA27 samples were compressed at the same testing temperatures. Due to microstructural changes, a significant strength degradation of solid ZA27 was observed starting at 100 °C. Comparison of results indicates that the temperature-dependent mechanical properties of P-MSF and G-MSF are strongly controlled by the matrix material. However, the addition of particles decreased the relative reduction of plateau stress and volumetric energy absorption of ZA27 MSF at elevated temperatures.

Compressive properties of zinc syntactic foams at elevated temperatures

Al99.5 and AlSi12 matrix syntactic foams were produced by pressure infiltration of Globocer grade ceramic hollow spheres. The produced aluminium matrix syntactic foams (AMSFs) were investigated by compressive tests, dynamic mechanical analysis (DMA), finite element methods (DMA) and elasticity based analytical calculations. The aim of the investigations was (i) to map the compressive properties of the AMSFs, (ii) to determine and compare the effective Young's modulus of the AMSFs determined by compressive tests, DMA, FEM and analytical calculations and (iii) to determine the low frequency damping capability of the AMSFs. The compressive tests showed pronounced differences between the two matrix materials, characterized by higher compressive strength, compressive strain and absorbed mechanical energy in the case of AlSi12 matrix, however, the energy absorption efficiency due to the different failure mechanism of AMSFs (homogeneous densification in the case of Al99.5 and cleavage in the case of AlSi12 matrix, respectively). The DMA tests confirmed the effective Young's moduli values, measured by compression and proved higher damping capability in the case of AlSi12 matrix. FEM and analytical calculations also confirmed the measured effective Young's moduli within a reasonable error band.

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Compressive characteristics and low frequency damping of aluminium matrix syntactic foams

\n The objective of this review paper is to summarize the current status and identify the knowledge gaps in ceramic binder jetting additive manufacturing, with a particular focus on density. This paper begins with an overview of ceramic binder jetting. Then, it discusses different aspects of density, including various terminologies, measurement methods, and achieved values. Afterward, it reviews two categories of techniques to increase the part density: material preparation techniques (powder granulation, mixing powders of different sizes, using slurry feedstock, and mixing different materials) and postprocessing techniques (sintering, chemical reaction, infiltration, and isostatic pressing). Finally, it presents the knowledge gaps in the literature.

Ceramic Binder Jetting Additive Manufacturing: A Literature Review on Density

Aluminum alloy matrix syntactic foams were produced by inert gas pressure infiltration. Four different alloys and ceramic hollow spheres were applied as matrix and filler material, respectively. The effects of the chemical composition of the matrix and the different heat-treatments are reported at different strain-rates and in compressive loadings. The higher strain rates were performed in a Split-Hopkinson pressure bar system. The results show that, the characteristic properties of the materials strongly depends on the chemical composition of the matrix and its heat-treatment condition. The compressive strength of the investigated foams showed a limited sensitivity to the strain rate, its effect was more pronounced in the case of the structural stiffness and fracture strain. The failure modes of the foams have explicit differences showing barreling and shearing in the case of quasi-static and high strain rate compression respectively.

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Quasi-static and high strain rate response of aluminum matrix syntactic foams under compression

The present research work has investigated the synthesis of ceramic structures based on inorganic, spherical-hollow microballoons using a binder jet printing process. Binder jet printing is a process that allows the synthesis process of complex and intricate parts with minimal waste of the feedstock material. The ceramic microballoons here investigated were based on a mullite derivative. The printed ceramic parts were cured and sintered as the precursor templates for metal matrix syntactic foams (MMSFs). The MMSFs were manufactured by infiltrating the printed ceramic templates by molten aluminum. The flexural strength of the cured, sintered, and infiltrated structures were also investigated. It is proposed that binder jet printing followed by a sintering and pressureless infiltration process represents an advantageous technology for designing complex MMSF structures.

Structure property relationship of metal matrix syntactic foams manufactured by a binder jet printing process

Mechanical modeling based on numerical homogenization of an Al2O3/Al composite manufactured via binder jet printing

Structure-Property Relationship of Binder Jetted Fused Silica Preforms to Manufacture Ceramic-Metallic Interpenetrating Phase Composites

Geometrically-complex and lightweight ceramic parts manufactured via 3D printing are prospective structures that seem to provide excellent thermal, wear and dielectric performance. In the present work, binder jetted parts based on synthetic lightweight ceramic hollow microspheres were manufactured and evaluated under different testing conditions in order to characterize their mechanical performance. The resulting structures were assessed in terms of quasi-static flexural and compressive strength, and density. Furthermore, microscopy analyses highlighted the composition of the final structures and fracture mechanisms. The printed system mainly consisted of aluminum silicon dioxide, fly ash and traces of metal. The samples yielded similar strength as that achieved on conventional bulk-based 3D printed ceramic structures. It was observed that the strength of the printed microspheres increased by sintering the parts to near-fusion temperatures due to viscous flow of material during sintering. The combination of the proposed process and feedstock represents an attractive manufacturing method for fabricating lightweight structures for applications like composite tooling molds, electromagnetic devices, and biomedical implants.

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Kyle Myers

Papers

Quasi-static and high strain rate response of aluminum matrix syntactic foams under compression

Structure property relationship of metal matrix syntactic foams manufactured by a binder jet printing process

Mechanical modeling based on numerical homogenization of an Al2O3/Al composite manufactured via binder jet printing

Structure-Property Relationship of Binder Jetted Fused Silica Preforms to Manufacture Ceramic-Metallic Interpenetrating Phase Composites

Mechanical performance of lightweight ceramic structures via binder jetting of microspheres