New Partially Water-Soluble Feedstocks for Additive Manufacturing of Ti6Al4V Parts by Material Extrusion

Eickhoff, Ralf; Nötzel, Dorit; Hanemann, Thomas

doi:10.3390/ma16083162

Materials

2023

DOI: 10.3390/ma16083162

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New Partially Water-Soluble Feedstocks for Additive Manufacturing of Ti6Al4V Parts by Material Extrusion

Ralf Eickhoff

Dorit Nötzel

Thomas Hanemann

Abstract: In this work, a process chain for the realization of dense Ti6Al4V parts via different material extrusion methods will be introduced applying eco-friendly partially water-soluble binder systems. In continuation of earlier research, polyethylene glycol (PEG) as a low molecular weight binder component was combined either with poly(vinylbutyral) (PVB) or with poly(methylmethacrylat) (PMMA) as a high molecular weight polymer and investigated with respect to their usability in FFF and FFD. The additional investigat… Show more

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Cited by 3 publications

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Printing, Debinding and Sintering of 15-5PH Stainless Steel Components by Fused Deposition Modeling Additive Manufacturing

Chang,

Zhang,

et al. 2023

Materials

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Metal FDM technology overcomes the problems of high cost, high energy consumption and high material requirements of traditional metal additive manufacturing by combining FDM and powder metallurgy and realizes the low-cost manufacturing of complex metal parts. In this work, 15-5PH stainless steel granules with a powder content of 90% and suitable for metal FDM were developed. The flowability and formability of the feedstock were investigated and the parts were printed. A two-step (solvent and thermal) debinding process is used to remove the binder from the green part. After being kept at 75 °C in cyclohexane for 24 h, the solvent debinding rate reached 98.7%. Following thermal debinding, the material’s weight decreased by slightly more than 10%. Sintering was conducted at 1300 °C, 1375 °C and 1390 °C in a hydrogen atmosphere. The results show that the shrinkage of the sintered components in the X-Y-Z direction remains quite consistent, with values ranging from 13.26% to 19.58% between 1300 °C and 1390 °C. After sintering at 1390 °C, the material exhibited a relative density of 95.83%, a hardness of 101.63 HRBW and a remarkable tensile strength of 770 MPa. This work realizes the production of metal parts using 15-5PH granules’ extrusion additive manufacturing, providing a method for the low-cost preparation of metal parts. And it provides a useful reference for the debinding and sintering process settings of metal FDM. In addition, it also enriches the selection range of materials for metal FDM.

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Printing, Debinding and Sintering of 15-5PH Stainless Steel Components by Fused Deposition Modeling Additive Manufacturing

Chang,

Zhang,

et al. 2023

Materials

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Development of a Polyethylene Glycol/Polymethyl Methacrylate-Based Binder System for a Borosilicate Glass Filler Suitable for Injection Molding

Zürn,

Schrage,

Antusch

et al. 2024

Materials

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Powder injection molding is an established, cost effective and often near-net-shape mass production process for metal or ceramic parts with complex geometries. This paper deals with the extension of the powder injection molding process chain towards the usage of a commercially available borosilicate glass and the realization of glass compounds with huge densities. The whole process chain consists of the individual steps of compounding, molding, debinding, and sintering. The first part, namely, the search for a suitable feedstock composition with a very high solid load and reliable molding properties, is mandatory for the successful manufacture of a dense glass part. The most prominent feature is the binder composition and the related comprehensive rheological characterization. In this work, a binder system consisting of polyethylene glycol and polymethylmethacrylate with stearic acid as a surfactant was selected and its suitability for glass injection molding was evaluated. The influence of all feedstock components on processing and of the process steps on the final sintered part was investigated for sintered glass parts with densities around 99% of the theoretical value.

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Material Extrusion 3D Printing of PEEK-Based Composites

et al. 2023

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High-performance thermoplastics like polyetheretherketone (PEEK), with their outstanding thermal stability, mechanical properties and chemical stability, have great potential for various structural applications. Combining with additive manufacturing methods extends further PEEK usage, e.g., as a mold insert material in polymer melt processing like injection molding. Mold inserts must possess a certain mechanical stability, a low surface roughness as well as a good thermal conductivity for the temperature control during the molding process. With this in mind, the commercially available high-performance thermoplastic PEEK was doped with small amounts of carbon nanotubes (CNT, 6 wt%) and copper particles (10 wt%) targeting enhanced thermomechanical properties and a higher thermal conductivity. The composites were realized by a commercial combined compounder and filament maker for the usage in a material extrusion (MEX)-based 3D-printer following the fused filament fabrication (FFF) principle. Commercial filaments made from PEEK and carbon fiber reinforced PEEK were used as reference systems. The impact of the filler and the MEX printing conditions like printing temperature, printing speed and infill orientation on the PEEK properties were characterized comprehensively by tensile testing, fracture imaging and surface roughness measurements. In addition, the thermal conductivity was determined by the laser-flash method in combination with differential scanning calorimetry and Archimedes density measurement. The addition of fillers did not alter the measured tensile strength in comparison to pure PEEK significantly. The fracture images showed a good printing quality without the MEX-typical voids between and within the deposited layers. Higher printing temperatures caused a reduction of the surface roughness and, in some cases, an enhanced ductile behavior. The thermal conductivity could be increased by the addition of the CNTs. Following the given results, the most critical process step is the compounding procedure, because for a reliable process–parameter–property relationship, a homogeneous particle distribution in the polymer matrix yielding a reliable filament quality is essential.

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New Partially Water-Soluble Feedstocks for Additive Manufacturing of Ti6Al4V Parts by Material Extrusion

Cited by 3 publications

References 46 publications

Printing, Debinding and Sintering of 15-5PH Stainless Steel Components by Fused Deposition Modeling Additive Manufacturing

Printing, Debinding and Sintering of 15-5PH Stainless Steel Components by Fused Deposition Modeling Additive Manufacturing

Development of a Polyethylene Glycol/Polymethyl Methacrylate-Based Binder System for a Borosilicate Glass Filler Suitable for Injection Molding

Material Extrusion 3D Printing of PEEK-Based Composites

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