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

2020 ◽  
Vol 46 (10) ◽  
pp. 16966-16972 ◽  
Author(s):  
Mohammadamin Moghadasi ◽  
Wenchao Du ◽  
Ming Li ◽  
Zhijian Pei ◽  
Chao Ma
Keyword(s):  
Particle Size ◽  
Additive Manufacturing ◽  
Final Part ◽  
Feedstock Powder ◽  
Ceramic Binder ◽  
Binder Jetting

Binder Jetting Additive Manufacturing of Ceramics: Feedstock Powder Preparation by Spray Freeze Granulation

2019 ◽  
Author(s):  
Wenchao Du ◽  
Guanxiong Miao ◽  
Lianlian Liu ◽  
Zhijian Pei ◽  
Chao Ma
Keyword(s):  
Particle Size ◽  
Additive Manufacturing ◽  
Feed Rate ◽  
Freeze Drying ◽  
Granule Size ◽  
Feedstock Powder ◽  
Powder Preparation ◽  
Promising Technology ◽  
Spray Freeze Drying ◽  
Binder Jetting

Abstract Objective of this study is to prepare the binder jetting feedstock powder by spray freeze drying and study the effects of its parameters on the powder properties. Binder jetting additive manufacturing is a promising technology for fabricating ceramic parts with complex or customized geometries. However, this process is limited by the relatively low density of the fabricated parts even after sintering. The main cause comes from the contradicting requirements of the particle size of the feedstock powder: a large particle size (> 5 μm) is required for a high flowability while a small particle size (< 1 μm) for a high sinterability. For the first time, a novel technology for the feedstock material preparation, called spray freeze drying, is investigated to address this contradiction. Using raw alumina nanopowder (100 nm), a full factorial design at two levels for two factors (spraying pressure and slurry feed rate) was formed to study their effects on the properties (i.e., granule size, flowability, and sinterability) of the obtained granulated powder. Results show that high pressure and small feed rate lead to small granule size. Compared with the raw powder, the flowability of the granulated powders was significantly increased, and the high sinterability was also maintained. This study proves that spray freeze granulation is a promising technology for the feedstock powder preparation of binder jetting additive manufacturing.

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

2020 ◽  
Vol 36 ◽  
pp. 101542 ◽  
Author(s):  
Guanxiong Miao ◽  
Wenchao Du ◽  
Mohammadamin Moghadasi ◽  
Zhijian Pei ◽  
Chao Ma
Keyword(s):  
Additive Manufacturing ◽  
Feedstock Powder ◽  
Ceramic Binder ◽  
Binder Jetting

scholarly journals Effect of Particle Size Distribution on Powder Packing and Sintering in Binder Jetting Additive Manufacturing of Metals

2017 ◽  
Vol 139 (8) ◽  
Author(s):  
Yun Bai ◽  
Grady Wagner ◽  
Christopher B. Williams
Keyword(s):  
Particle Size ◽  
Additive Manufacturing ◽  
Large Degree ◽  
Full Density ◽  
Powder Particle Size ◽  
Powder Mixtures ◽  
Fine Powders ◽  
Sintering Shrinkage ◽  
The Impact ◽  
Binder Jetting

The binder jetting additive manufacturing (AM) process provides an economical and scalable means of fabricating complex parts from a wide variety of materials. While it is often used to fabricate metal parts, it is typically challenging to fabricate full density parts without large degree of sintering shrinkage. This can be attributed to the inherently low green density and the constraint on powder particle size imposed by challenges in recoating fine powders. To address this issue, the authors explored the use of bimodal powder mixtures in the context of binder jetting of copper. A variety of bimodal powder mixtures of various particle diameters and mixing ratios were printed and sintered to study the impact of bimodal mixtures on the parts' density and shrinkage. It was discovered that, compared to parts printed with monosized fine powders, the use of bimodal powder mixtures improves the powder's packing density (8.2%) and flowability (10.5%), and increases the sintered density (4.0%) while also reducing the sintering shrinkage (6.4%).

scholarly journals Structure and Properties of Barium Titanate Lead-Free Piezoceramic Manufactured by Binder Jetting Process

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4419
Author(s):  
Vadim Sufiiarov ◽  
Artem Kantyukov ◽  
Anatoliy Popovich ◽  
Anton Sotov
Keyword(s):  
Particle Size ◽  
Additive Manufacturing ◽  
Barium Titanate ◽  
Manufacturing Process ◽  
Lead Free ◽  
Density Values ◽  
Binder Saturation ◽  
Binder Jetting ◽  
Titanate Lead ◽  
Functional Ceramics

This article presents the results of manufacturing samples from barium titanate (BaTiO3) lead-free piezoceramics by using the binder jetting additive manufacturing process. An investigation of the manufacturing process steps for two initial powders with different particle size distributions was carried. The influence of the sintering and the particle size distribution of the starting materials on grain size and functional properties was evaluated. Samples from fine unimodal powder compared to coarse multimodal one have 3–4% higher relative density values, as well as a piezoelectric coefficient of 1.55 times higher values (d33 = 183 pC/N and 118 pC/N correspondingly). The influence of binder saturation on sintering modes was demonstrated. Binder jetting with 100% saturation for both powders enables printing samples without delamination and cracking. Sintering at 1400 °C with a dwell time of 6 h forms the highest density samples. The microstructure of sintered samples was characterized with scanning electron microscopy. The possibility of manufacturing parts from functional ceramics using additive manufacturing was demonstrated.

scholarly journals Ceramic Binder Jetting Additive Manufacturing: A Literature Review on Density

2020 ◽  
Vol 142 (4) ◽  
Author(s):  
Wenchao Du ◽  
Xiaorui Ren ◽  
Zhijian Pei ◽  
Chao Ma
Keyword(s):  
Additive Manufacturing ◽  
Review Paper ◽  
Measurement Methods ◽  
Current Status ◽  
Knowledge Gaps ◽  
Ceramic Binder ◽  
Part Density ◽  
Preparation Techniques ◽  
Material Preparation ◽  
Binder Jetting

Abstract 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.

scholarly journals A STRUCTURED APPROACH TO REDUCE DESIGN ITERATIONS IN ADDITIVE MANUFACTURING

2021 ◽  
Vol 1 ◽  
pp. 231-240
Author(s):  
Laura Wirths ◽  
Matthias Bleckmann ◽  
Kristin Paetzold
Keyword(s):  
Additive Manufacturing ◽  
Spare Parts ◽  
Design Guidelines ◽  
Final Part ◽  
Layer By Layer ◽  
Powder Bed ◽  
Batch Sizes ◽  
Manufacturing Technologies ◽  
Structured Approach ◽  
Design Freedom

AbstractAdditive Manufacturing technologies are based on a layer-by-layer build-up. This offers the possibility to design complex geometries or to integrate functionalities in the part. Nevertheless, limitations given by the manufacturing process apply to the geometric design freedom. These limitations are often unknown due to a lack of knowledge of the cause-effect relationships of the process. Currently, this leads to many iterations until the final part fulfils its functionality. Particularly for small batch sizes, producing the part at the first attempt is very important. In this study, a structured approach to reduce the design iterations is presented. Therefore, the cause-effect relationships are systematically established and analysed in detail. Based on this knowledge, design guidelines can be derived. These guidelines consider process limitations and help to reduce the iterations for the final part production. In order to illustrate the approach, the spare parts production via laser powder bed fusion is used as an example.

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