New insights on the porous network created during solvent debinding of powder injection-molded (PIM) parts, and its influence on the thermal debinding efficiency

Rolère, Sébastien; Soupremanien, Ulrich; Bohnke, Marc; Dalmasso, Myriam; Delafosse, C.; Laucournet, Richard

doi:10.1016/j.jmatprotec.2021.117163

Cited by 21 publications

(11 citation statements)

References 40 publications

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“…In contrast, specimens with covers reach a debinding plateau between 6 and 12 h, depending on the infill grade. Adding a cover decreases the debinding rate because of the reduction of the exposed surface of the specimens, as demonstrated in several studies for powder injection moulded parts [65][66][67][68][69]. For specimens without cover, the outer surface and the surface of the infill structure are in direct contact with the solvent and most of the binder is removed in the initial steps of debinding.…”

Section: D Printing and Solvent Debindingmentioning

confidence: 99%

Bending Properties of Lightweight Copper Specimens with Different Infill Patterns Produced by Material Extrusion Additive Manufacturing, Solvent Debinding and Sintering

González-Gutiérrez

Cano

Ecker³

et al. 2021

Applied Sciences

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Material extrusion additive manufacturing (MEX) is a versatile technology for producing complex specimens of polymers, ceramics and metals. Highly-filled filaments composed of a binder system and a high-volume content of sinterable powders are needed to produce ceramic or metal parts. After shaping the parts via MEX, the binder is removed and the specimens are sintered to obtain a dense part of the sintered filler particles. In this article, the applicability of this additive manufacturing process to produce copper specimens is demonstrated. The particular emphasis is on investigating the production of lightweight specimens that retain mechanical properties without increasing their weight. The effect of infill grades and the cover presence on the debinding process and the flexural properties of the sintered parts was studied. It was observed that covers could provide the same flexural strength with a maximum weight reduction of approximately 23%. However, a cover on specimens with less than 100% infill significantly slows down the debinding process. The results demonstrate the applicability of MEX to produce lightweight copper specimens.

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Section: D Printing and Solvent Debindingmentioning

confidence: 99%

Bending Properties of Lightweight Copper Specimens with Different Infill Patterns Produced by Material Extrusion Additive Manufacturing, Solvent Debinding and Sintering

González-Gutiérrez

Cano

Ecker³

et al. 2021

Applied Sciences

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“…To form ceramic parts with high mechanical properties, the green part first needs to go through the de-binding process. De-binding refers to the removal of parts other than the solid content in the ceramic slurry system by a thermal de-binding − or solvent de-binding method. , De-binding of the green part is the longest time-consuming step in the process of additive manufacturing via the light-curing method of ceramic materials, and various defects such as cracking, delamination, deformation, and collapse easily appear in this process, which affects the integrity of products and reduces the mechanical properties of materials. Therefore, the de-binding process is the key step in the forming process of SiO 2 ceramic products.…”

Section: Resultsmentioning

confidence: 99%

Research on Rheology and Formability of SiO₂ Ceramic Slurry Based on Additive Manufacturing Technology via a Light Curing Method

Fang

Yan

2022

ACS Omega

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SiO 2 ceramic parts with complex structures were formed by additive manufacturing technology via a light curing method combined with a heat treatment process. To reveal the influence mechanism of rheology and formability of SiO 2 ceramic slurry, the microstructure, morphology, and properties of light-cured SiO 2 ceramic samples were characterized by a viscosity test, thermogravimetric analysis (TG-DTG), X-ray diffraction (XRD), a scanning electron microscope (SEM), and a series of tests for physical properties (bending strength, mass burning rate, and densification). The results indicate that the main effect of the dispersant-type factor was more significant than the pH value. When the dispersant was ammonium polyacrylate (PMAA-NH 4 ) with a content of 1.0 wt % and the pH value of the slurry system was 9, the viscosity of SiO 2 ceramic slurry could be controlled to the lowest. It was also found that the sintering temperature in the experiment had no effect on the crystalline phase of SiO 2 ceramics. When the sintering temperature was 1250 °C and the solid content was 65 vol %, the micromorphology of the samples was uniform. Under this condition, the bending strength of the sample reached 14.9 MPa and the densification was 76.43%.

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“…Debinding is more critical for LPIM feedstock without backbone or with a minor amount of backbone since the part is more fragile. Frequent debinding techniques include solvent debinding and thermal debinding [183][184][185][186], which are discussed in Section 5.1. In lacking a backbone binder for some LPIM feedstocks, shape retention is one of the process' most significant challenges; thus, an alternative method for debinding in LPIM is thermal wick debinding, in which all binder components are eliminated in a single operation in a bed of loosely packed powder.…”

Section: Debindingmentioning

confidence: 99%

Research Progress on Low-Pressure Powder Injection Molding

et al. 2022

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Powder injection molding (PIM) is a well-known technique to manufacture net-shaped, complicated, macro or micro parts employing a wide range of materials and alloys. Depending on the pressure applied to inject the feedstock, this process can be separated into low-pressure (LPIM) and high-pressure (HPIM) injection molding. Although the LPIM and HPIM processes are theoretically similar, all steps have substantial differences, particularly feedstock preparation, injection, and debinding. After decades of focusing on HPIM, low-viscosity feedstocks with improved flowability have recently been produced utilizing low-molecular-weight polymers for LPIM. It has been proven that LPIM can be used for making parts in low quantities or mass production. Compared to HPIM, which could only be used for the mass production of metallic and ceramic components, LPIM can give an outstanding opportunity to cover applications in low or large batch production rates. Due to the use of low-cost equipment, LPIM also provides several economic benefits. However, establishing an optimal binder system for all powders that should be injected at extremely low pressures (below 1 MPa) is challenging. Therefore, various defects may occur throughout the mixing, injection, debinding, and sintering stages. Since all steps in the process are interrelated, it is important to have a general picture of the whole process which needs a scientific overview. This paper reviews the potential of LPIM and the characteristics of all steps. A complete academic and research background survey on the applications, challenges, and prospects has been indicated. It can be concluded that although many challenges of LPIM have been solved, it could be a proper solution to use this process and materials in developing new applications for technologies such as additive manufacturing and processing of sensitive alloys.

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New insights on the porous network created during solvent debinding of powder injection-molded (PIM) parts, and its influence on the thermal debinding efficiency

Cited by 21 publications

References 40 publications

Bending Properties of Lightweight Copper Specimens with Different Infill Patterns Produced by Material Extrusion Additive Manufacturing, Solvent Debinding and Sintering

Bending Properties of Lightweight Copper Specimens with Different Infill Patterns Produced by Material Extrusion Additive Manufacturing, Solvent Debinding and Sintering

Research on Rheology and Formability of SiO₂ Ceramic Slurry Based on Additive Manufacturing Technology via a Light Curing Method

Research Progress on Low-Pressure Powder Injection Molding

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New insights on the porous network created during solvent debinding of powder injection-molded (PIM) parts, and its influence on the thermal debinding efficiency

Cited by 21 publications

References 40 publications

Bending Properties of Lightweight Copper Specimens with Different Infill Patterns Produced by Material Extrusion Additive Manufacturing, Solvent Debinding and Sintering

Bending Properties of Lightweight Copper Specimens with Different Infill Patterns Produced by Material Extrusion Additive Manufacturing, Solvent Debinding and Sintering

Research on Rheology and Formability of SiO2 Ceramic Slurry Based on Additive Manufacturing Technology via a Light Curing Method

Research Progress on Low-Pressure Powder Injection Molding

Contact Info

Product

Resources

About

Research on Rheology and Formability of SiO₂ Ceramic Slurry Based on Additive Manufacturing Technology via a Light Curing Method