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

Challenges in additive manufacturing of high-strength aluminium alloys and current developments in hybrid additive manufacturing

Microstructure formation and mechanical properties of ODS steels built by laser additive manufacturing of nanoparticle coated iron-chromium powders

Industry 40 being the new face of manufacturing for future, metal additive manufacturing is a key element in this framework For metal additive manufacturing, laser-based additive manufacturing techniques are dominating today However, some of the inherent technical limitations associated with these techniques lead to a significant gap between the industrial requirements and the final deliverables Additive friction stir deposition is a promising alternative that is still in its early stages of development This review summarizes the vital findings in AFSD with particular emphasis on microstructure evolution and physical properties The technical limitations of laser-based AM techniques are discussed to describe the role of AFSD in their domain AFSD is discussed sequentially covering the basic physical process, features, capabilities, and limitations AFSD, being a solid-state thermomechanical process, results in a refined equiaxed microstructure with enhanced mechanical properties and no signs of porosity and residual stresses In addition to this, AFSD is capable of depositing large scale components at a high build rate that leads to cost and energy-efficient fabrication The existing limitations of the process are discussed with the scope for future improvements This critical review concludes with the suggested strategies for the widespread adoption of AFSD

Innovative potential of additive friction stir deposition among current laser based metal additive manufacturing processes: A review

Additive manufacturing of ceramics is still at an early-development stage; however, the huge interest in custom production of these materials has led to the development of different techniques that could provide highly performing devices. In this work, alumina (α-Al2O3) components were produced by binder jetting 3D printing (BJ), a powder-based technique that enables the ex-situ thermal treatment of the printed parts. The employment of fine particles has led to high green relative density values (>60 %), as predicted by Lubachevsky-Stillinger algorithm and DEM modelling. Then, extended sintering has been observed on samples treated at 1750 °C that have reached a final density of 75.4 %. Finally, the mechanical properties of the sintered material have been assessed through bending test for flexural resistance and micro-indentation for Vickers hardness evaluation.

3D printing of fine alumina powders by binder jetting

In general, melting process is not a common method for the production of oxide dispersion strengthened (ODS) alloys due to agglomeration and coarsening of oxide particles. However, vacuum casting process has recently been employed as a promising process to produce micro-scale oxide dispersed alloys. In this paper, we report the process and characterization of in situ formation and uniform dispersion of nano-scale Y-Ti oxide particles in Fe-10Ni-7Mn (wt.%) alloy. The processing route involves a solid-liquid reaction between the added TiO2 as an oxygen carrier and dissolved yttrium in liquid metal leading to an optimal microstructure with nano-sized dispersed oxide particles. The developed thermodynamic model shows the independence of the final phase constituents from experimental conditions such as melting temperature or vacuum system pressure which offers a general pathway for the manufacture of oxide dispersion strengthened materials.

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Development of an oxide-dispersion-strengthened steel by introducing oxygen carrier compound into the melt aided by a general thermodynamic model.

Because of its high sinterability, nanopowder could be beneficial for ceramic binder jetting additive manufacturing to achieve a high density on printed and sintered parts. However, the flowability of nanopowder is poor because of the large interparticle cohesion. This poor flowability prohibits the usage of nanopowder in ceramic binder jetting. In this study, to improve the flowability of nanopowder, alumina nanoparticles were granulated into micron-sized granules through spray freeze drying. The raw nanopowder and granulated powder were compared by characterizing their flowability and printability. Results showed that the granulated powder had a much better flowability than the raw nanopowder. Because of the superior flowability, the granulated powder formed a denser and smoother powder bed than the raw nanopowder and resulted in denser and smoother printed and sintered samples. These improvements indicated that the printability of nanopowder was improved by granulation.

Ceramic binder jetting additive manufacturing: Effects of granulation on properties of feedstock powder and printed and sintered parts

Ceramic binder jetting additive manufacturing: Effects of particle size on feedstock powder and final part properties

Ceramic binder jetting additive manufacturing: Relationships among powder properties, feed region density, and powder bed density

http://manuscript.elsevier.com/S152661252200353X/pdf/S152661252200353X.pdf

Mohammadamin Moghadasi

Papers

Development of an oxide-dispersion-strengthened steel by introducing oxygen carrier compound into the melt aided by a general thermodynamic model.

Ceramic binder jetting additive manufacturing: Effects of granulation on properties of feedstock powder and printed and sintered parts

Ceramic binder jetting additive manufacturing: Effects of particle size on feedstock powder and final part properties

Ceramic binder jetting additive manufacturing: Relationships among powder properties, feed region density, and powder bed density

Experimental investigation on the effect of roller traverse and rotation speeds on ceramic binder jetting additive manufacturing