Study of Metal Powder Extrusion and Accumulating Rapid Prototyping

Li, Ji Bin; Zhan, Xie; Zhang, Xiao Hui; Zeng, Qinghua; Liu, Hai Jun

doi:10.4028/www.scientific.net/kem.443.81

Cited by 11 publications

(7 citation statements)

References 2 publications

(1 reference statement)

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“…During the extrusion, the frequent buckling failures cause interruption of the process; the backpressure encountered during the deposition limits the powder volume fraction in the filament, reducing the possibility of successful sintering of the produced part. Due to these problems, the FDM concept has been transformed by some authors, using as a starting material a ceramic clay or a metal slurry [7] instead of a plastic filament and replacing the torque and pinch system with a piston or screw injector [8] [9]. However, the use of a metal or ceramic slurry or feedstock still has some limitations, especially in terms of the minimum diameter of the extrusion nozzle.…”

Section: Introductionmentioning

confidence: 99%

An innovative machine for Fused Deposition Modeling of metals and advanced ceramics

Giberti

Strano

Annoni

2016

MATEC Web of Conferences

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Abstract. The design of a new additive manufacturing (AM) system based on extrusion and 3D deposition of a mixture of metal (or advanced ceramic) powder and polymeric binder is described in this paper. The proposed system is totally innovative in terms of combination of deposited work material, extrusion system (head and nozzle), and deposition work table, which is based on a 5-axes parallel kinematics machine (PKM). The extrusion head and nozzle have been designed in order to be able to extrude high viscosity mixtures with low polymeric content. The 5-axes PKM is aimed at obtaining a good surface quality of the deposited work and reducing the need for supports during deposition. After the deposition, the material is de-binded and sintered to nearly the density of the solid material ascast. The design and kinematics of the machine and especially the PKM table is described in this paper, the main design issues are discussed and some preliminary extrusion and sintering results are presented.

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Section: Introductionmentioning

confidence: 99%

An innovative machine for Fused Deposition Modeling of metals and advanced ceramics

Giberti

Strano

Annoni

2016

MATEC Web of Conferences

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“…The microhardness value of the part developed as a proof of concept (PoC, Fig. 18) was 1.1 GPa, which is higher than those of other studies for the same material on MEX [37]. Nevertheless, the microhardness values are lower than those measured in a PIM made from SS 316L and a bulk steel part [30,38].…”

Section: Proof Of Conceptmentioning

confidence: 80%

“…POCI-01-0247-FEDER-024533]; and this research is sponsored by Fig. 18 Microhardness of the proof of concept (PoC) part in comparison with other data [30,37,38]…”

Section: Discussionmentioning

confidence: 99%

Optimization of metallic powder filaments for additive manufacturing extrusion (MEX)

Cerejo

Gatões

Vieira

2021

Int J Adv Manuf Technol

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Additive manufacturing (AM) of metallic powder particles has been establishing itself as sustainable, whatever the technology selected. Material extrusion (MEX) integrates the ongoing effort to improve AM sustainability, in which low-cost equipment is associated with a decrease of powder waste during manufacturing. MEX has been gaining increasing interest for building 3D functional/structural metallic parts because it incorporates the consolidated knowledge from powder injection moulding/extrusion feedstocks into the AM scope—filament extrusion layer-by-layer. Moreover, MEX as an indirect process can overcome some of the technical limitations of direct AM processes (laser/electron-beam-based) regarding energy-matter interactions. The present study reveals an optimal methodology to produce MEX filament feedstocks (metallic powder, binder, and additives), having in mind to attain the highest metallic powder content. Nevertheless, the main challenges are also to achieve high extrudability and a suitable ratio between stiffness and flexibility. The metallic powder volume content (vol.%) in the feedstocks was evaluated by the critical powder volume concentration (CPVC). Subsequently, the rheology of the feedstocks was established by means of the mixing torque value, which is related to the filament extrudability performance.

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“…A research group of Shenzhen University initially proposed to implement an FDM process using the same feedstock material mix in use for powder injection molding machines [51]. They used a stainless steel powder and thermoplastic paraffin wax-based binder, extruded through a screw extruder and they started studying the material properties of the green and sintered extruded filaments.…”

Section: D Printing Of Advanced Ceramics and Metals Starting From Pel...mentioning

confidence: 99%

A comprehensive review of extrusion-based additive manufacturing processes for rapid production of metallic and ceramic parts

2019

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An extrusion based additive manufacturing (EAM) technique, recently became competitive for the rapid production of metals and ceramics components. This is made possible by extruding the metal or ceramic material in solid powder form, mixed with a binder, i.e. an expendable viscous fluid, which is removed from the part after 3D printing. The strength of these technologies relies on the large design freedom allowed by and by the cost efficiency advantage vs. alternative metal additive manufacturing processes based on high energy beams, e.g. laser/electron beam.EAM of metals and ceramics is not yet widespread, and the published scientific and technical literature is rapidly growing, but still less extensive than the literature on FDM of plastics or SLM of metals. This paper aims at filling this gap. Fused Deposition Modeling (FDM) and Powder Injection Molding (PIM) are identified as preceding or enabling technologies for EAM. This paper systematically reviews all the aspects of feedstock extrusion-based AM processes used for production of complex shaped parts. Then, the unique characteristics and advantages of the process are discussed, with respect to materials and process steps. The key process parameters are explained to illustrate the suitability of the process for diverse domains of applications.

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Study of Metal Powder Extrusion and Accumulating Rapid Prototyping

Cited by 11 publications

References 2 publications

An innovative machine for Fused Deposition Modeling of metals and advanced ceramics

An innovative machine for Fused Deposition Modeling of metals and advanced ceramics

Optimization of metallic powder filaments for additive manufacturing extrusion (MEX)

A comprehensive review of extrusion-based additive manufacturing processes for rapid production of metallic and ceramic parts

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