Binder Jetting Additive Manufacturing of Ceramics: A Literature Review

2017 ◽  
Author(s):  
Wenchao Du ◽  
Xiaorui Ren ◽  
Chao Ma ◽  
Zhijian Pei
Keyword(s):  
Additive Manufacturing ◽  
Literature Review ◽  
Process Parameters ◽  
Material Properties ◽  
Raw Materials ◽  
High Hardness ◽  
Ceramic Materials ◽  
Future Research ◽  
Binder Jetting ◽  
Resultant Material

Ceramic materials are more difficult to process than metals and polymers using additive manufacturing technologies because of their high melting temperature, high hardness and brittleness. Binder jetting additive manufacturing has been used to fabricate ceramic parts for various applications. This paper presents a literature review on recent advances in ceramic binder jetting. The paper begins with listing applications and material properties investigated in reported studies followed by the effects of raw materials and process parameters on resultant material properties. Raw materials include binder (material, application method, concentration, and saturation) and ceramic feedstock (preparation method, quality metrics, and particle size and shape), and process parameters include layer thickness and postprocessing method. Resultant material properties of interest include density, strength, hardness, and toughness. This review will provide guidance for the selection of raw materials and process parameters to obtain desired material properties for various applications. This paper is concluded by proposing future research directions.

scholarly journals SURFACE ROUGHNESS CONSIDERATIONS IN DESIGN FOR ADDITIVE MANUFACTURING - A LITERATURE REVIEW

2021 ◽  
Vol 1 ◽  
pp. 2841-2850
Author(s):  
Didunoluwa Obilanade ◽  
Christo Dordlofva ◽  
Peter Törlind
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Literature Review ◽  
Future Research ◽  
Reduction Potentials ◽  
Research Fields ◽  
Post Process ◽  
Accessibility Issues ◽  
End Use ◽  
And Performance

AbstractOne often-cited benefit of using metal additive manufacturing (AM) is the possibility to design and produce complex geometries that suit the required function and performance of end-use parts. In this context, laser powder bed fusion (LPBF) is one suitable AM process. Due to accessibility issues and cost-reduction potentials, such ‘complex’ LPBF parts should utilise net-shape manufacturing with minimal use of post-process machining. The inherent surface roughness of LPBF could, however, impede part performance, especially from a structural perspective and in particular regarding fatigue. Engineers must therefore understand the influence of surface roughness on part performance and how to consider it during design. This paper presents a systematic literature review of research related to LPBF surface roughness. In general, research focuses on the relationship between surface roughness and LPBF build parameters, material properties, or post-processing. Research on design support on how to consider surface roughness during design for AM is however scarce. Future research on such supports is therefore important given the effects of surface roughness highlighted in other research fields.

Learning Algorithm Based Modeling and Process Parameters Recommendation System for Binder Jetting Additive Manufacturing Process

2015 ◽  
Author(s):  
Han Chen ◽  
Yaoyao F. Zhao
Keyword(s):  
Additive Manufacturing ◽  
Product Quality ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Process Model ◽  
Recommendation System ◽  
Powder Materials ◽  
Quality Properties ◽  
Binder Jetting ◽  
Printing Time

Binder Jetting (BJ) process is an additive manufacturing process in which powder materials are selectively joined by binder materials. Products can be manufactured layer by layer directly from 3D model data. It is not always easy for manufacturing engineers to choose proper BJ process parameters to meet the end-product quality and fabrication time requirements. This is because the quality properties of the products fabricated by BJ process are significantly affected by the process parameters. And the relationships between process parameters and quality properties are very complicated. In this paper, a process model is developed by Backward Propagation (BP) Neural Network (NN) algorithm based on 16 groups of orthogonal experiment designed by Taguchi Method to express the relationships between 4 key process parameters and 2 key quality properties. Based on the modeling results, an intelligent parameters recommendation system is developed to predict end-product quality properties and printing time, and to recommend process parameters selection based on the process requirements. It can be used as a guideline for selecting the proper printing parameters in BJ to achieve the desired properties and help to reduce the printing time.

A Review on Additive Manufacturing of Ceramics

2019 ◽  
Author(s):  
Brooke Mansfield ◽  
Sabrina Torres ◽  
Tianyu Yu ◽  
Dazhong Wu
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Computer Aided Design ◽  
Ceramic Materials ◽  
Complex Geometries ◽  
Laminated Object Manufacturing ◽  
Challenges And Opportunities ◽  
Aided Design ◽  
Binder Jetting

Abstract Additive manufacturing (AM), also known as 3D printing, has been used for rapid prototyping due to its ability to produce parts with complex geometries from computer-aided design files. Currently, polymers and metals are the most commonly used materials for AM. However, ceramic materials have unique mechanical properties such as strength, corrosion resistance, and temperature resistance. This paper provides a review of recent AM techniques for ceramics such as extrusion-based AM, the mechanical properties of additively manufactured ceramics, and the applications of ceramics in various industries, including aerospace, automotive, energy, electronics, and medical. A detailed overview of binder-jetting, laser-assisted processes, laminated object manufacturing (LOM), and material extrusion-based 3D printing is presented. Finally, the challenges and opportunities in AM of ceramics are identified.

scholarly journals Impacts of process-induced porosity on material properties of copper made by binder jetting additive manufacturing

2019 ◽  
Vol 182 ◽  
pp. 108001 ◽  
Author(s):  
Ashwath Yegyan Kumar ◽  
Jue Wang ◽  
Yun Bai ◽  
Scott T. Huxtable ◽  
Christopher B. Williams
Keyword(s):  
Additive Manufacturing ◽  
Material Properties ◽  
Binder Jetting

scholarly journals ADDITIVE MANUFACTURING RESEARCH LANDSCAPE: A LITERATURE REVIEW

2021 ◽  
Vol 1 ◽  
pp. 333-344
Author(s):  
Pascal Schmitt ◽  
Stefan Zorn ◽  
Kilian Gericke
Keyword(s):  
Additive Manufacturing ◽  
Literature Review ◽  
Business Models ◽  
Cost Savings ◽  
Future Research ◽  
Successful Implementation ◽  
Research Activities ◽  
New Business ◽  
Market Opportunities ◽  
Function Integration

AbstractAdditive manufacturing offers several potentials such as the freedom of design, part consolidation, function integration, or time and cost-savings. These potentials make AM interesting for industries such as aerospace, automotive and medical implants, and are also seen as enables for the creation of entirely new business models. Additive manufacturing has the potential to change the current manufacturing landscape substantially and has attracted much attention of industry and academia over the last decades.However, these developments require improvements concerning the technology itself and its successful implementation into the value creation chain. Driven by the promising market opportunities and upcoming technological developments, many research activities started.This paper presents a literature review of publications from the last 20 years. Based on this analysis, the evolution of the AM research landscape is portrayed. The research landscape is organised into four areas: machine and process, material, digital process chain and methodology. The paper summarises developments in each of these areas and concludes by presenting current and discussing future research topics.

Process parameters optimization for improving surface quality and manufacturing accuracy of binder jetting additive manufacturing process

2016 ◽  
Vol 22 (3) ◽  
pp. 527-538 ◽  
Author(s):  
Han Chen ◽  
Yaoyao Fiona Zhao
Keyword(s):  
Additive Manufacturing ◽  
Product Quality ◽  
Process Parameters ◽  
Parameters Optimization ◽  
Powder Materials ◽  
Optimal Parameters ◽  
Content Type ◽  
Quality Properties ◽  
Printing Parameters ◽  
Binder Jetting

Purpose Binder jetting (BJ) process is an additive manufacturing (AM) process in which powder materials are selectively joined by binder materials. Products can be manufactured layer-by-layer directly from three-dimensional model data. The quality properties of the products fabricated by the BJ AM process are significantly affected by the process parameters. To improve the product quality, the optimal process parameters need to be identified and controlled. This research works with the 420 stainless steel powder material. Design/methodology/approach This study focuses on four key printing parameters and two end-product quality properties. Sixteen groups of orthogonal experiment designed by the Taguchi method are conducted, and then the results are converted to signal-to-noise ratios and analyzed by analysis of variance. Findings Five sets of optimal parameters are concluded and verified by four group confirmation tests. Finally, by taking the optimal parameters, the end-product quality properties are significantly improved. Originality/value These optimal parameters can be used as a guideline for selecting proper printing parameters in BJ to achieve the desired properties and help to improve the entire BJ process ability.

scholarly journals ВИБІР ПАРАМЕТРІВ ПРОЦЕСУ СЕЛЕКТИВНОГО ЛАЗЕ-РНОГО ПЛАВЛЕННЯ ДЛЯ МЕТАЛЕВИХ ПОРОШКІВ

2021 ◽  
pp. 48-58
Author(s):  
В. Є. Зайцев ◽  
А. С. Полупан
Keyword(s):  
Mechanical Properties ◽  
Titanium Alloys ◽  
Process Parameters ◽  
Material Properties ◽  
Complex Geometry ◽  
Production Costs ◽  
Protective Atmosphere ◽  
Future Research ◽  
Structural Elements ◽  
Scanning Strategy

The article deals with the issues of determining the optimal parameters of the selective laser melting (SLM) process in order to develop a technology for manufacturing aircraft structural elements from titanium alloys. This literature review notes the advantages of titanium alloys, which have higher specific strength and corrosion resistance compared to most steels and aluminum alloys. It is determined that traditional methods of forming titanium parts lead to a large amount of material waste, high production costs and long production times. It is noted that the SLM technology makes it possible to create parts of titanium alloys with complex geometry. It is also emphasized that the titanium glory Ti-6Al-4V is the most popular titanium alloy used in aircraft construction. This paper presents a description of the SLM process and a list of parameters that affect design and final material properties. Attention is drawn to the main parameters of SLM: energy density, process temperature (temperature of the building platform), environmental conditions, material properties and scanning strategy. The influence of the above parameters of the SLM process on product quality and production time is shown. Finding the optimal values for the SLM process parameters is an important step in creating a part that is manufactured to obtain priority mechanical properties. The need is stressed to employed a protective atmosphere during the process is emphasized, the use of internal gases (nitrogen, argon and helium) to prevent oxidation, significantly affects the process, the final mechanical properties and microstructure of the parts produced. It is shown that for the production of high-quality products, it is important that the metal powder has a spherical grain shape and a size not exceeding the thickness of one applied layer. The build chamber temperature should be varied depending on the desired mechanical properties of the final product. Variable process parameters (scanning strategy, laser parameters) affect the thermal balance, productivity, geometric accuracy of porosity, which affects the mechanical properties and microstructure. This analysis of foreign experience and future research will further improve the technology for the production of aircraft structural elements.

Development of Trends and Methodologies for Shaping Ceramics by Electrical Discharge Machining: A Review

2019 ◽  
Author(s):  
Asif Rashid ◽  
Muhammad P. Jahan ◽  
Asma Perveen ◽  
Jianfeng Ma
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
High Hardness ◽  
High Strength ◽  
Ceramic Materials ◽  
Machining Process ◽  
Future Research ◽  
Great Resistance ◽  
Hard And Brittle Materials ◽  
Superior Corrosion Resistance

Abstract Ceramic materials possess excellent properties like high hardness, superior corrosion resistance and great resistance to wear. These materials are low in density and demonstrate high strength to wear ratio. There is an increasing need to machine these hard and brittle materials as they have various engineering applications. The distinguishing properties of ceramics do not allow them to be machined by conventional processes. Electrical discharge machining (EDM) is a non-conventional process and a viable option to machine and generate complex shapes in hard materials. EDM can be used on materials irrespective of its hardness and wear resistance as it is a non-contact machining process and no active force is applied between the workpiece and electrode during machining. As EDM requires the workpiece to be electrically conductive, machining ceramics by this process is a challenge. Alterations need to be carried out in order for insulating ceramics to be machined by this process. This paper discusses the basics of EDM process and its control parameters. A classification of ceramic materials based on their electrical conductivity is established and their relevance to the respective material removal mechanisms have been identified. Different approaches to successfully machine ceramics by EDM have been reviewed. The challenges and modifications of each method have been discussed. An outline and expectations for machining a particular ceramic material and its composites have been generated. Finally, the prospects of future research in this area have been identified.

Binder Jetting Additive Manufacturing of Ceramics: Analytical and Numerical Models for Powder Spreading Process

2019 ◽  
Author(s):  
Guanxiong Miao ◽  
Wenchao Du ◽  
Zhijian Pei ◽  
Chao Ma
Keyword(s):  
Additive Manufacturing ◽  
Numerical Models ◽  
Ceramic Materials ◽  
Low Density ◽  
Forming Process ◽  
Spreading Process ◽  
Powder Bed ◽  
Complex Shapes ◽  
Part Density ◽  
Binder Jetting

Abstract Binder jetting additive manufacturing is a promising way to process ceramic materials which are hard to be manufactured into complex shapes using conventional methods. However, the application of binder jetting is limited by the relatively low density of manufactured parts. Powder bed forming process is a critical step that determines the powder bed density and consequently the part density. Thus, investigating and understanding the power spreading process is necessary to improve the part density. A numerical model is developed to predict the powder bed density under different spreading conditions using the discrete element method (DEM). The predicted DEM results are compared with the prediction of an analytical model. The results show that under different layer thicknesses (50 μm, 70 μm, 100 μm) and roller diameters (12 mm, 14 mm, and 16 mm), the predicted maximum powder bed density by these two models has nearly the same value and the predicted maximum packing stress has the same trend.

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