Binder jetting additive manufacturing: Three-dimensional simulation of micro-meter droplet impact and penetration into powder bed

2022 ◽  
Vol 74 ◽  
pp. 365-373
Author(s):  
Hongxin Deng ◽  
Yanlu Huang ◽  
Shibiao Wu ◽  
Yongqiang Yang
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Droplet Impact ◽  
Powder Bed ◽  
Dimensional Simulation ◽  
Binder Jetting

scholarly journals Material Reuse in Laser Powder Bed Fusion: Side Effects of the Laser—Metal Powder Interaction

Metals ◽  
2020 ◽  
Vol 10 (3) ◽  
pp. 341 ◽  
Author(s):  
Eleonora Santecchia ◽  
Stefano Spigarelli ◽  
Marcello Cabibbo
Keyword(s):  
Additive Manufacturing ◽  
Side Effects ◽  
Metal Powder ◽  
Three Dimensional ◽  
High Energy ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Metal Additive Manufacturing ◽  
Metal Additive

Metal additive manufacturing is changing the way in which engineers and designers model the production of three-dimensional (3D) objects, with rapid growth seen in recent years. Laser powder bed fusion (LPBF) is the most used metal additive manufacturing technique, and it is based on the efficient interaction between a high-energy laser and a metal powder feedstock. To make LPBF more cost-efficient and environmentally friendly, it is of paramount importance to recycle (reuse) the unfused powder from a build job. However, since the laser–powder interaction involves complex physics phenomena and generates by-products which might affect the integrity of the feedstock and the final build part, a better understanding of the overall process should be attained. The present review paper is focused on the clarification of the interaction between laser and metal powder, with a strong focus on its side effects.

scholarly journals Review of Powder Bed Fusion Additive Manufacturing for Metals

Metals ◽  
2021 ◽  
Vol 11 (9) ◽  
pp. 1391
Author(s):  
Leila Ladani ◽  
Maryam Sadeghilaridjani
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Disruptive Technology ◽  
Powder Bed ◽  
Powder Particles ◽  
Metallic Parts ◽  
The Cost ◽  
Scientific Questions ◽  
Metal Additive

Additive manufacturing (AM) as a disruptive technology has received much attention in recent years. In practice, however, much effort is focused on the AM of polymers. It is comparatively more expensive and more challenging to additively manufacture metallic parts due to their high temperature, the cost of producing powders, and capital outlays for metal additive manufacturing equipment. The main technology currently used by numerous companies in the aerospace and biomedical sectors to fabricate metallic parts is powder bed technology, in which either electron or laser beams are used to melt and fuse the powder particles line by line to make a three-dimensional part. Since this technology is new and also sought by manufacturers, many scientific questions have arisen that need to be answered. This manuscript gives an introduction to the technology and common materials and applications. Furthermore, the microstructure and quality of parts made using powder bed technology for several materials that are commonly fabricated using this technology are reviewed and the effects of several process parameters investigated in the literature are examined. New advances in fabricating highly conductive metals such as copper and aluminum are discussed and potential for future improvements is explored.

Thermofluid Properties of Ti-6Al-4V Melt Pool in Powder-Bed Electron Beam Additive Manufacturing

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
M Shafiqur Rahman ◽  
Paul J. Schilling ◽  
Paul D. Herrington ◽  
Uttam K. Chakravarty
Keyword(s):  
Electron Beam ◽  
Additive Manufacturing ◽  
Heat Source ◽  
Thermal Behavior ◽  
Source Parameters ◽  
Three Dimensional ◽  
Full Density ◽  
Layer By Layer ◽  
Powder Bed ◽  
Melt Pool

Electron beam additive manufacturing (EBAM) is a powder-bed fusion additive manufacturing (AM) technology that can make full density metallic components using a layer-by-layer fabrication method. To build each layer, the EBAM process includes powder spreading, preheating, melting, and solidification. The quality of the build part, process reliability, and energy efficiency depends typically on the thermal behavior, material properties, and heat source parameters involved in the EBAM process. Therefore, characterizing those properties and understanding the correlations among the process parameters are essential to evaluate the performance of the EBAM process. In this study, a three-dimensional computational fluid dynamics (CFD) model with Ti-6Al-4V powder was developed incorporating the temperature-dependent thermal properties and a moving conical volumetric heat source with Gaussian distribution to conduct the simulations of the EBAM process. The melt pool dynamics and its thermal behavior were investigated numerically, and results for temperature profile, melt pool geometry, cooling rate and variation in density, thermal conductivity, specific heat capacity, and enthalpy were obtained for several sets of electron beam specifications. Validation of the model was performed by comparing the simulation results with the experimental results for the size of the melt pool.

Wire + Arc Additive Manufacturing of Metals

2020 ◽  
pp. 106-126
Author(s):  
Krishna Kishore Mugada ◽  
Aravindan Sivanandam ◽  
Ravi Kumar Digavalli
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Manufacturing Sector ◽  
Manufacturing Processes ◽  
Deposition Rates ◽  
Direct Energy Deposition ◽  
Powder Bed ◽  
Direct Energy ◽  
Wire Arc Additive Manufacturing ◽  
Binder Jetting

Wire + Arc additive manufacturing (WAAM) processes have become popular because of their proven capabilities to produce large metallic components with high deposition rates (promoted by arc-based processes) compared to conventional additive manufacturing processes such as powder bed fusion, binder jetting, direct energy deposition, etc. The applications of WAAM processes were constantly increasing in the manufacturing sector, which necessitates an understanding of the process capability to various metals. This chapter outlines the significant outcomes of the WAAM process for most of the engineering metals in terms of microstructure and mechanical properties. Discussion on various defects associated with the processed components is also presented. Potential application of WAAM for different metals such as aluminum and its alloys, titanium, and steels was discussed. The research indicates that the components manufactured by the WAAM process have significant microstructural changes and improved mechanical properties.

Thermal Analysis of Electron Beam Additive Manufacturing Using Ti-6Al-4V Powder-Bed

2017 ◽  
Author(s):  
M. Shafiqur Rahman ◽  
Paul J. Schilling ◽  
Paul D. Herrington ◽  
Uttam K. Chakravarty
Keyword(s):  
Electron Beam ◽  
Additive Manufacturing ◽  
Three Dimensional ◽  
Vital Role ◽  
Full Density ◽  
Rate Variation ◽  
Layer By Layer ◽  
Powder Bed ◽  
Part Quality ◽  
Melt Pool

Electron Beam Additive Manufacturing (EBAM) is one of the emerging additive manufacturing (AM) technologies that is uniquely capable of making full density metallic components using layer-by-layer fabrication method. To build each layer, the process includes powder spreading, pre-heating, melting, and solidification. The thermal and material properties involved in the EBAM process play a vital role to determine the part quality, reliability, and energy efficiency. Therefore, characterizing the properties and understanding the correlations among the process parameters are incumbent to evaluate the performance of the EBAM process. In this study, a three dimensional computational fluid dynamics (CFD) model with Ti-6Al-4V powder has been developed incorporating the temperature-dependent thermal properties and a moving conical volumetric heat source with Gaussian distribution to conduct the simulations of the EBAM process. The melt-pool dynamics and its thermal behavior have been investigated numerically using a CFD solver and results for temperature profile, cooling rate, variation in density, thermal conductivity, specific heat capacity, and enthalpy have been obtained for a particular set of electron beam specifications.

Binder Jetting Additive Manufacturing of Metals: A Literature Review

2019 ◽  
Author(s):  
Ming Li ◽  
Wenchao Du ◽  
Alaa Elwany ◽  
Zhijian Pei ◽  
Chao Ma
Keyword(s):  
Additive Manufacturing ◽  
Dimensional Accuracy ◽  
Binding Agent ◽  
Metal Part ◽  
Spreading Process ◽  
Powder Bed ◽  
The Past ◽  
Wide Range ◽  
Binder Jetting ◽  
Two Parameter

Abstract Binder jetting, also known as 3D printing, is an additive manufacturing (AM) technology utilizing a liquid-based binding agent to selectively join the material in a powder bed. It is capable of manufacturing complex-shaped parts with a variety of materials. This paper provides an overview of binder jetting of metals with a discussion about the knowledge gaps and research opportunities. The review deals with two parameter categories in terms of the material and process and their impacts. The achieved density, dimensional accuracy, and mechanical strength are summarized and analyzed. Further in-depth consideration of densification is discussed corresponding to various attributes of the packing, printing, and sintering behaviors. Though binder jetting has attracted increasing attention in the past several years, this fabrication process is not well studied. The understanding of powder spreading process and binder-powder interaction is crucial to the development of binder jetting but insufficient. In addition, the lack of investigation on the mechanical behavior of binder jetting metal part restricts the actualization of its wide-range applications.

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