Powder content in powder extrusion moulding of tool steel: Dimensional stability, shrinkage and hardness

González-Gutiérrez, Joamín; Thompson, Yvonne; Handl, D. M.; Cano, Santiago Cano; Schuschnigg, Stephan; Felfer, Peter; Kukla, Christian; Holzer, Clemens; Burkhardt, Carlo

doi:10.1016/j.matlet.2020.128909

Cited by 12 publications

(7 citation statements)

References 6 publications

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“…Recently, new machines that can work with pellets of metal injection molding (MIM) feedstocks have been developed, and research is being carried out to maximize the performance of the printed specimens with steels [45], hard metals [40], and copper [46]. The advantages of using filament feedstocks are low-cost shaping equipment [47], availability of powders used in traditional powder metallurgical processes, and same feedstock materials are usable in metal injection molding (MIM) or metal extrusion molding (MEM) [48]. It is also easy to prepare multi-material parts when co-sintering is possible [15,49,50].…”

Section: Introductionmentioning

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: Introductionmentioning

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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“…The focus of the present investigation is on highly filled polymers with up to 60 vol.% of sinterable particles. One of the major applications of highly filled polymers with more than 40 vol.% is the indirect fabrication of metal, ceramic, or cermet parts with complex geometry in processes like powder injection moulding (PIM) [13], powder extrusion moulding (PEM) [14,15], and more recently, powder fused filament fabrication (PFFF) [10]. All these technologies follow three main steps after the preparation of the highly filled thermoplastic compound.…”

Section: Introductionmentioning

confidence: 99%

Rheological Behaviour of Highly Filled Materials for Injection Moulding and Additive Manufacturing: Effect of Particle Material and Loading

et al. 2020

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Within this paper, we are dealing with a mixture of thermoplastic polymer that is filled with inorganic fillers at high concentrations up to 60 vol.%. A high number of particles in the compound can substantially change the rheological behaviour of the composite and can lead to problems during processing in the molten state. The rheological behaviour of highly filled materials is complex and influenced by many interrelated factors. In the present investigation, we considered four different spherical materials: steel, aluminium alloy, titanium alloy and glass. Particles with similar particle size distribution were mixed with a binder system at different filling grades (30–60 vol.%). We showed that the rheological behaviour of highly filled materials is significantly dependent on the chemical interactions between the filler and matrix material. Moreover, it was shown that the changes of the particle shape and size during processing lead to unexpected rheological behaviour of composite materials as it was observed in the composites filled with glass beads that broke at high contents during processing.

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“…This rate needs to be applied between 170 and 550 °C to give enough time for binder degradation and evaporation. It is lower than applied heating rates for steel-loaded filaments with the same binder [ 10 , 29 ]. The adapted heating rate is necessary for thermal debinding in atmospheres with low oxygen partial pressure (pO2), whereas debinding in air was successful also at higher rates up to 1.0 °C min −1 in this study.…”

Section: Resultsmentioning

confidence: 99%

Metal fused filament fabrication of the nickel-base superalloy IN 718

et al. 2022

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This study demonstrates metal fused filament fabrication (MF3) as an alternative additive and highly flexible manufacturing method for free-form fabrication of high-performance alloys. This novel processing, which is similar to Metal injection molding (MIM), enables a significant reduction in manufacturing costs for complex geometries, since expensive machining can be avoided. Utilizing existing equipment and reducing material expense, MF3 can pave the way for new and low-cost applications of IN 718, which were previously limited by high manufacturing costs. Iterative process optimization is used to find the most suitable MF3 process parameters. High relative density above 97% after pressureless sintering can be achieved if temperature profiles and atmospheres are well adjusted for thermal debinding and sintering. In this study, the influence of processing parameters on the resulting microstructure of MF3 IN 718 is investigated. Samples sintered in vacuum show coarse-grained microstructure with an area fraction of 0.36% NbC at grain boundaries. Morphology and composition of formed precipitates are analyzed using transmission electron microscopy and atom probe tomography. The γ/γ″/γ′ phases’ characteristics for IN 718 were identified. Conventional heat treatment is applied for further tailoring of mechanical properties like hardness, toughness and creep behavior. Fabricated samples achieve mechanical properties similar to MIM IN 718 presented in literature. Graphical abstract

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Powder content in powder extrusion moulding of tool steel: Dimensional stability, shrinkage and hardness

Cited by 12 publications

References 6 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

Rheological Behaviour of Highly Filled Materials for Injection Moulding and Additive Manufacturing: Effect of Particle Material and Loading

Metal fused filament fabrication of the nickel-base superalloy IN 718

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