Influence of shape distortion on the precision of holes in parts fabricated by metal binder jetting
Springer Science and Business Media LLC - Trang 1-12
Tóm tắt
Metal binder jetting (MBJ) is an additive manufacturing (AM) technology split into two process steps: printing and sintering. Firstly, product is built up layer-by-layer by the selective deposition of a binder agent on a powder bed. Secondly, a thermal treatment (sintering) consolidates the metal structure. MBJ is currently becoming more and more attractive on the reason of high potential scalability, cost-effective production and wide range of available material feedstocks. However, the transition towards industrial scale production is restrained by the critical control of dimensional and geometrical precision of parts after sintering operation. In fact, product geometry is affected by anisotropic dimensional change or even shape distortion. This study aims at investigating the dimensional and geometrical precision of through holes. Three sample geometries were designed, having a through hole with axis perpendicular to the building direction and located at different levels along sample height. Samples were measured by a coordinate measuring machine before and after sintering, in order to assess the shrinkage and any shape change. Results highlight the inhomogeneous volumetric and linear shrinkage of the three geometries, which is influenced by the printing position in the building plane. A macroscopic deformation of parallelepiped geometry was also evidenced, caused by the superposition of layer shifting originated on printing, and by the frictional forces between sample surface and alumina support during sintering. Such distortion significantly affects the shrinkage and form error of holes.
Tài liệu tham khảo
citation_journal_title=Int. J. Interact. Des. Manuf.; citation_title=Integrated CAD platform approach for design for additive manufacturing of high performance automotive components; citation_author=E Dalpadulo, F Pini, F Leali; citation_volume=14; citation_publication_date=2020; citation_pages=899-909; citation_doi=10.1007/s12008-020-00684-7; citation_id=CR1
citation_journal_title=Int. J. Interact. Des. Manuf.; citation_title=Additive manufacturing: expanding 3D printing horizon in industry 4.0; citation_author=G Prashar, H Vasudev, D Bhuddhi; citation_publication_date=2022; citation_doi=10.1007/s12008-022-00956-4; citation_id=CR2
citation_journal_title=Addit. Manuf.; citation_title=Binder jetting: a review of process, materials, and methods; citation_author=M Ziaee, NB Crane; citation_volume=28; citation_publication_date=2019; citation_pages=781-801; citation_doi=10.1016/j.addma.2019.05.031; citation_id=CR3
citation_journal_title=J. Manufact. Sci. Eng.; citation_title=Metal binder jetting additive manufacturing : a literature review; citation_author=M Li, W Du, A Elwany, Z Pei, C Ma; citation_volume=142; citation_publication_date=2020; citation_pages=1-17; citation_doi=10.1115/1.4047430; citation_id=CR4
citation_journal_title=Addit. Manuf.; citation_title=Impact of part thickness and drying conditions on saturation limits in binder jet additive manufacturing; citation_author=NB Crane; citation_volume=33; citation_publication_date=2020; citation_pages=101127; citation_doi=10.1016/j.addma.2020.101127; citation_id=CR5
citation_journal_title=Powder Metall.; citation_title=A review on recent developments in binder jetting metal additive manufacturing: materials and process characteristics; citation_author=A Lores, N Azurmendi, I Agote, E Zuza; citation_volume=62; citation_publication_date=2019; citation_pages=267-296; citation_doi=10.1080/00325899.2019.1669299; citation_id=CR6
citation_journal_title=Mater. Sci. Eng. A.; citation_title=Effects of process parameters, debinding and sintering on the microstructure of 316L stainless steel produced by binder jetting; citation_author=N Lecis, M Mariani, R Beltrami, L Emanuelli, R Casati, M Vedani, A Molinari; citation_volume=828; citation_publication_date=2021; citation_pages=142108; citation_doi=10.1016/j.msea.2021.142108; citation_id=CR7
citation_journal_title=J. Manuf. Sci. Eng.; citation_title=Metal binder jetting additive manufacturing: a literature review; citation_author=M Li, W Du, A Elwany, Z Pei, C Ma; citation_volume=142; citation_publication_date=2020; citation_pages=1-17; citation_doi=10.1115/1.4047430; citation_id=CR8
citation_journal_title=J. Manuf. Sci. Eng. Trans. ASME.; citation_title=Effect of particle size distribution on powder packing and sintering in binder jetting additive manufacturing of metals; citation_author=Y Bai, G Wagner, CB Williams; citation_volume=139; citation_publication_date=2017; citation_pages=1-15; citation_doi=10.1115/1.4036640; citation_id=CR9
citation_journal_title=Mater. Des.; citation_title=Effect of powder size distribution on densification and microstructural evolution of binder-jet 3D-printed alloy 625; citation_author=A Mostafaei, P Rodriguez De Vecchis, I Nettleship, M Chmielus; citation_volume=162; citation_publication_date=2019; citation_pages=375-383; citation_doi=10.1016/j.matdes.2018.11.051; citation_id=CR10
citation_journal_title=J. Mech. Des. Trans. ASME.; citation_title=Manufacturability analysis of flatness tolerances in solid freeform fabrication; citation_author=R Arni, SK Gupta; citation_volume=123; citation_publication_date=2001; citation_pages=148-156; citation_doi=10.1115/1.1326439; citation_id=CR11
citation_journal_title=J. Manuf. Syst.; citation_title=Optimal part orientation in Rapid Manufacturing process for achieving geometric tolerances; citation_author=R Paul, S Anand; citation_volume=30; citation_publication_date=2011; citation_pages=214-222; citation_doi=10.1016/j.jmsy.2011.07.010; citation_id=CR12
citation_journal_title=Int. J. Adv. Manuf. Technol.; citation_title=Cylindricity and flatness optimization for mechanical parts in additive manufacturing based on tolerance adaptive slicing; citation_author=Q Chen, J Xu, S Zhang; citation_volume=115; citation_publication_date=2021; citation_pages=3839-3857; citation_doi=10.1007/s00170-021-07271-4; citation_id=CR13
citation_journal_title=Metals; citation_title=Analysis of the flatness form error in binder jetting process as affected by the inclination angle; citation_author=M Zago, N Lecis, M Mariani, I Cristofolini; citation_volume=12; citation_issue=3; citation_publication_date=2022; citation_pages=430; citation_doi=10.3390/met12030430; citation_id=CR14
citation_journal_title=Mech. Eng.; citation_title=Process development for green part printing using binder jetting additive manufacturing, Front; citation_author=H Miyanaji, M Orth, JM Akbar, L Yang; citation_volume=13; citation_publication_date=2018; citation_pages=504-512; citation_doi=10.1007/s11465-018-0508-8; citation_id=CR15
citation_journal_title=J. Mater. Process. Technol.; citation_title=Experimental and theoretical investigation on ultra-thin powder layering in three dimensional printing (3DP) by a novel double-smoothing mechanism; citation_author=S Cao, Y Qiu, XF Wei, HH Zhang; citation_volume=220; citation_publication_date=2015; citation_pages=231-242; citation_doi=10.1016/j.jmatprotec.2015.01.016; citation_id=CR16
citation_journal_title=Rapid Prototyp. J.; citation_title=Geometrical deviation identification and prediction method for additive manufacturing; citation_author=Z Huang, JY Dantan, A Etienne, M Rivette, N Bonnet; citation_volume=24; citation_publication_date=2018; citation_pages=1524-1538; citation_doi=10.1108/RPJ-07-2017-0137; citation_id=CR17
citation_journal_title=Int. J. Adv. Manuf. Technol.; citation_title=An experimental investigation into the dimensional error of powder-binder three-dimensional printing; citation_author=MN Islam, S Sacks; citation_volume=82; citation_publication_date=2016; citation_pages=1371-1380; citation_doi=10.1007/s00170-015-7482-7; citation_id=CR18
citation_journal_title=J. Ind. Technol.; citation_title=Three-dimensional printing build variables that impact cylindricity; citation_author=T Ollison, K Berisso; citation_volume=26; citation_publication_date=2010; citation_pages=1-10; citation_id=CR19
citation_journal_title=Addit. Manuf.; citation_title=Characterization of channels made by laser powder bed fusion and binder jetting using X-ray CT and image analysis; citation_author=T Dahmen, CG Klingaa, S Baier-Stegmaier, A Lapina, DB Pedersen, JH Hattel; citation_volume=36; citation_publication_date=2020; citation_pages=101445; citation_doi=10.1016/j.addma.2020.101445; citation_id=CR20
citation_journal_title=Addit. Manuf.; citation_title=Dimensional and geometrical precision of parts produced by Binder Jetting process as affected by the anisotropic shrinkage on sintering; citation_author=M Zago, NFM Lecis, M Vedani, I Cristofolini; citation_volume=43; citation_publication_date=2021; citation_pages=102007; citation_id=CR21
citation_title=Geometrical Issues in Design for Binder Jetting – The Effect of Anisotropic Dimensional Change on Sintering; citation_inbook_title=Des Tools Methods Ind. Eng. II; citation_publication_date=2022; citation_pages=410-421; citation_id=CR22; citation_author=M Zago; citation_author=NFM Lecis; citation_author=M Vedani; citation_author=I Cristofolini; citation_publisher=Springer International Publishing
citation_journal_title=Addit. Manuf.; citation_title=Numerical simulation and experimental measurement of pressureless sintering of stainless steel part printed by Binder Jetting Additive Manufacturing; citation_author=K Zhang, W Zhang, R Brune, E Herderick, X Zhang, J Cornell, J Forsmark; citation_volume=47; citation_publication_date=2021; citation_pages=102330; citation_doi=10.1016/j.addma.2021.102330; citation_id=CR23
citation_journal_title=Mater. Des.; citation_title=Numerical simulation of shrinkage and deformation during sintering in metal binder jetting with experimental validation; citation_author=S Sadeghi Borujeni, A Shad, K Abburi Venkata, N Günther, V Ploshikhin; citation_volume=216; citation_publication_date=2022; citation_pages=110490; citation_doi=10.1016/j.matdes.2022.110490; citation_id=CR24
citation_journal_title=J. Micromechanics Mol. Phys.; citation_title=A computational framework for modeling distortion during sintering of binder jet printed parts; citation_author=BJ Paudel, D Conover, JK Lee, AC To; citation_volume=6; citation_publication_date=2021; citation_pages=95-102; citation_doi=10.1142/S242491302142008X; citation_id=CR25
citation_journal_title=Int. J. Interact. Des. Manuf.; citation_title=Controlling form errors in 3D printed models associated to size and position on the working plane; citation_author=F Vitolo, M Martorelli, S Gerbino, S Patalano, A Lanzotti; citation_volume=12; citation_publication_date=2018; citation_pages=969-977; citation_doi=10.1007/s12008-017-0441-9; citation_id=CR26
citation_journal_title=Jom.; citation_title=Binder-Jet Printing of Fine Stainless Steel Powder with Varied Final Density; citation_author=M Ziaee, EM Tridas, NB Crane; citation_volume=69; citation_publication_date=2017; citation_pages=592-596; citation_doi=10.1007/s11837-016-2177-6; citation_id=CR27
citation_journal_title=Acta Mater.; citation_title=Anisotropic shrinkage induced by particle rearrangement in sintering; citation_author=F Wakai, K Chihara, M Yoshida; citation_volume=55; citation_publication_date=2007; citation_pages=4553-4566; citation_doi=10.1016/j.actamat.2007.04.027; citation_id=CR28
citation_journal_title=Addit. Manuf.; citation_title=The effects of sintering temperature and hold time on densification, mechanical properties and microstructural characteristics of binder jet 3D printed 17–4 PH stainless steel; citation_author=D Huber, L Vogel, A Fischer; citation_volume=46; citation_publication_date=2021; citation_pages=102114; citation_doi=10.1016/j.addma.2021.102114; citation_id=CR29
citation_journal_title=Powder Metall.; citation_title=Sintering anisotropy of binder jetted 316L stainless steel: part I – sintering anisotropy; citation_author=AC Rios, E Hryha, E Olevsky, P Harlin; citation_volume=65; citation_issue=4; citation_publication_date=2021; citation_pages=273-282; citation_doi=10.1080/00325899.2021.2020485; citation_id=CR30
Lores, A., Azumendi, N., Agote, I., Andres, U.: A step towards a robust binder jetting technology: Process parameter optimization for 17–4 PH steel to increase powder bed homogeneity. In: Procedings Eur. 2020 Int. Powder Metall. Virtual Congr. Exhib. (2020).
citation_journal_title=Procedia Manuf.; citation_title=Improving Structural integrity with boron - based additives for 3D printed 420 stainless steel; citation_author=T Do, CS Shin, D Stetsko, G Vanconant, A Vartanian, S Pei, P Kwon; citation_volume=1; citation_publication_date=2015; citation_pages=263-272; citation_doi=10.1016/j.promfg.2015.09.019; citation_id=CR32
citation_journal_title=Mater. Today Commun.; citation_title=Influence of initial relative densities on the sintering behavior and mechanical behavior of 316 L stainless steel fabricated by binder jet 3D printing; citation_author=Z Chen, W Chen, L Chen, D Zhu, Q Chen, Z Fu; citation_volume=31; citation_publication_date=2022; citation_pages=103369; citation_doi=10.1016/j.mtcomm.2022.103369; citation_id=CR33
citation_journal_title=Powder Technol.; citation_title=Modeling of effect of powder spreading on green body dimensional accuracy in additive manufacturing by binder jetting; citation_author=AL Maximenko, ID Olumor, AP Maidaniuk, EA Olevsky; citation_volume=385; citation_publication_date=2021; citation_pages=60-68; citation_doi=10.1016/j.powtec.2021.02.070; citation_id=CR34
citation_journal_title=Acta Mater.; citation_title=Effect of gravity on dimensional change during sintering - II Shape distortion; citation_author=EA Olevsky, RM German, A Upadhyaya; citation_volume=48; citation_publication_date=2000; citation_pages=1167-1180; citation_doi=10.1016/S1359-6454(99)00369-9; citation_id=CR35