Fused Filament Fabrication (FFF) of Metal-Ceramic Components

Abel, Johannes; Scheithauer, Uwe; Janics, Thomas; Hampel, Stefan; Cano, Santiago Cano; Müller-Köhn, Axel; Günther, Anne; Kukla, Christian; Moritz, Tassilo

doi:10.3791/57693

Cited by 48 publications

(39 citation statements)

References 15 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…In all cases, voids within the structure and at the transition from infill to envelope can be seen as well as the layer-by-layer filament deposition within one layer and between subsequent deposited layers. The observed voids are typical for by FFF printed parts and can be found in current literature as well investigating composites and sintered metals [27][28][29][30], also observed in case of magnetic filler dispersed in a polymer matrix [31]. The presence of voids in the printed samples influences all physical properties: In case of mechanical testing, the mechanical properties are reduced because the voids acts as defect volume.…”

Section: Composite Printingmentioning

confidence: 54%

3D Printing of ABS Barium Ferrite Composites

2020

View full text Add to dashboard Cite

In this work, a process for the realization of new polymer matrix composites with nanosized barium ferrite (BaFe12O19) as ferrimagnetic filler, acryl butadiene styrene (ABS) as polymer matrix and an extrusion-based method, namely fused filament fabrication (FFF), as 3D printing method will be described comprehensively. The whole process consists of the individual steps material compounding, rheological testing, filament extrusion, 3D-printing via FFF and finally a widespread specimen characterization regarding to appearance, mechanical properties like tensile and bending behavior as well as the aspired magnetic properties. Increasing ferrite amounts up to 40 vol.% (equal 76 wt.%) cause a reduction of the ultimate stress and an increase of the magnetic polarization as well as of the energy product (BH)max in comparison to the pure polymer matrix. In addition, an extensive discussion of typical printing defects and their consequences on the device properties will be undertaken.

show abstract

Section: Composite Printingmentioning

confidence: 54%

3D Printing of ABS Barium Ferrite Composites

2020

View full text Add to dashboard Cite

show abstract

“…Increasing the layer thickness is equivalent to decreasing the number of layers and interlayer contacts. The interlayer contacts could be the weakest points of the printed specimens depending on the printing conditions, since there is an incomplete diffusion of polymer chains between adjacent strands, a reduced cross-section due to the introduction of voids, and fracture mechanic-type stress concentrations [43]. Therefore, decreasing the number of interfaces by increasing the layer thickness can increase the strength of the specimens [35].…”

Section: Statistical Analysis Of Tensile Strengthmentioning

confidence: 99%

Optimization of the 3D Printing Parameters for Tensile Properties of Specimens Produced by Fused Filament Fabrication of 17-4PH Stainless Steel

et al. 2020

Self Cite

View full text Add to dashboard Cite

Fused filament fabrication (FFF) combined with debinding and sintering could be an economical process for three-dimensional (3D) printing of metal parts. In this paper, compounding, filament making, and FFF processing of feedstock material with 55% vol. of 17-4PH stainless steel powder in a multicomponent binder system are presented. The experimental part of the paper encompasses central composite design for optimization of the most significant 3D printing parameters (extrusion temperature, flow rate multiplier, and layer thickness) to obtain maximum tensile strength of the 3D-printed specimens. Here, only green specimens were examined in order to be able to determine the optimal parameters for 3D printing. The results show that the factor with the biggest influence on the tensile properties was flow rate multiplier, followed by the layer thickness and finally the extrusion temperature. Maximizing all three parameters led to the highest tensile properties of the green parts.One of the most commonly used AM technologies for the production of metal parts is PBF. In PBF, a laser or electron beam selectively fuses metal powder or metal powder covered with a binding agent by scanning cross-sectional layers generated from a CAD file of the part on the surface of a powder bed. After one cross-section is scanned, the powder bed is lowered and a new layer of powder is added on top of the previous one; the process repeats until the part is finished [6]. One of the biggest disadvantages of PBF is that it relies on high-power lasers or high-energy electron beams, which can be very costly. In addition, the powder must be free-flowing and, therefore, it requires a specific powder distribution, which adds to the price of the material. Therefore, MEAM shows great promise as a cost-effective alternative since the shaping equipment is orders of magnitude cheaper than PBF [6], and powders with a great range of particle size distributions can be processed. In the most common type of MEAM, the building material is supplied in the form of spooled filaments and, therefore, is also known as fused filament fabrication (FFF). In most FFF machines, the filament is fed into a heating unit with a nozzle using counter-rotating rollers as a feeding system. The extrusion head is controlled to move in the XY plane, and, as it moves, material is extruded through the nozzle on a flat platform that moves in the Z-direction [5]. However, there are also MEAM systems, where the extrusion system is fixed and the printing platform moves in three axes [7], and systems where the printed head moves in three axes and the building platform is fixed [8].FFF was first developed for polymeric materials; however, for the fabrication of metal or ceramic parts, a filament made of a polymeric blend filled with a large portion of metal or ceramic particles, known as feedstock, is used. After shaping the filament into what is referred to as the green parts, the binder system is removed from the part by thermal, catalytic, or solvent extraction and then sintered to ob...

show abstract

“…Fused filament fabrication (FFF) is a thermoplastic AM technology which bases on nearly endless filaments which are used as a semi-finished products and which are melted and deposited under a heated nozzle. To generate ceramic components, particle-filled filaments are used to manufacture the so-called green bodies additively [14]. These green bodies have to be debinded, to remove all organic materials, and sintered to densify the microstructure and to achieve the typical ceramic properties.…”

Section: Fused Filament Fabrication (Fff)mentioning

confidence: 99%

“…The benefits of this AM technology are the high productivity and the large building space of the available devices. The existing challenges of FFF of ceramic components are the development of highly particle-filled filaments and the defectfree debinding and sintering of the components [14].…”

Section: Fused Filament Fabrication (Fff)mentioning

confidence: 99%

Potentials and Challenges of Additive Manufacturing Technologies for Heat Exchanger

Scheithauer¹,

Kordass²,

Noack³

et al. 2019

Advances in Heat Exchangers

Self Cite

View full text Add to dashboard Cite

The rapid development of additive manufacturing (AM) technologies enables a radical paradigm shift in the construction of heat exchangers. In place of a layout limited to the use of planar or tubular starting materials, heat exchangers can now be optimized, reflecting their function and application in a particular environment. The complexity of form is no longer a restriction but a quality. Instead of brazing elements, resulting in rather inflexible standard components prone to leakages, with AM, we finally can create seamless integrated and custom solutions from monolithic material. To address AM for heat exchangers we both focus on the processes, materials, and connections as well as on the construction abilities within certain modeling and simulation tools. AM is not the total loss of restrictions. Depending on the processes used, delicate constraints have to be considered. But on the other hand, we can access materials, which can operate in a much wider heat range. It is evident that conventional modeling techniques cannot match the requirements of a flexible and adaptive form finding. Instead, we exploit biomimetic and mathematical approaches with parametric modeling. This results in unseen configurations and pushes the limits of how we should think about heat exchangers today.

show abstract

Fused Filament Fabrication (FFF) of Metal-Ceramic Components

Cited by 48 publications

References 15 publications

3D Printing of ABS Barium Ferrite Composites

3D Printing of ABS Barium Ferrite Composites

Optimization of the 3D Printing Parameters for Tensile Properties of Specimens Produced by Fused Filament Fabrication of 17-4PH Stainless Steel

Potentials and Challenges of Additive Manufacturing Technologies for Heat Exchanger

Contact Info

Product

Resources

About