Uncovering microstructural heterogeneities in binder jet printed SS316L through ultrasonic testing and X-ray computed tomography

Cook, Olivia J.; Huang, Nancy; Smithson, Robert L.W.; Kube, Christopher M.; Beese, Allison M.; Argüelles, Andrea P.

doi:10.1016/j.matchar.2023.112697

Cited by 8 publications

(1 citation statement)

References 57 publications

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“…Therefore, a great alternative to these methods is a Binder Jetting technology, which does not use fusion but relies on a conglomeration of powder particles with a binding agent [3,7]. This method, unlike fusion-based methods, consists of shaping and a densification stage separately, resulting in reduced residual stresses and anisotropy [22][23][24].…”

Section: Introductionmentioning

confidence: 99%

Effect of the Particle Size Distribution of Irregular Al Powder on Properties of Parts for Electronics Fabricated by Binder Jetting

Marczyk

Hebda

2023

Electronics

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The present work analyzed the influence of the particle size of irregular aluminum powder on the properties of Binder-Jetting-printed parts, which can be used as electronic components. Powders of various particle sizes as well as blends in the ratio of 73–27 wt.% or 27–73 wt.% of coarse to fine powder particles were used. The parts were printed with constant parameters, such as a layer thickness of 120 µm, roller traverse speed of 10 mm/s, and binder saturation of 80%. For parts made of individual blends, analysis of the XRD, density, porosity, surface roughness, and dimensional changes in X, Y, and Z axes after the sintering process was conducted. The results confirmed the trend of smoothing the surface of 3D-printed parts with a reduction in the size of the powder particles used. The best results in terms of surface roughness were obtained for powder in which coarse particles (73%) had 50 µm and fine particles (27%) had 20 µm. However, the incorporation of coarser particles in an amount of 27 wt.% (AL160) to the fine-grained powder base (ALC100) allowed for the obtaining of details with higher density, lower total porosity, and relatively low surface roughness. The combination of these two powder particle sizes allowed the fine powder to fill the voids between the larger particles, resulting in properties that represent an excellent relationship between density, porosity, and surface quality. The research results indicate that the three-dimensional parts produced by Binder Jetting technology, through the phenomenal thermal conductivity of aluminum, can be successfully used as electronic components, such as heat sinks or transistor housings.

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Section: Introductionmentioning

confidence: 99%

Effect of the Particle Size Distribution of Irregular Al Powder on Properties of Parts for Electronics Fabricated by Binder Jetting

Marczyk

Hebda

2023

Electronics

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Resonant Ultrasonic Testing can Quantitatively Assess the Microscopic Porosity of Complex-Shaped Additively Manufactured AlSi10Mg Components

Skiadopoulos,

Prato,

Bozek

et al. 2024

J Nondestruct Eval

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The utility of resonant ultrasonic testing for quality control of complex-shaped additively manufactured (AM) components in terms of porosity variations is investigated. A fully noncontact test setup is used to investigate differences in the volumetric porosity between AM AlSi10Mg samples. A set of 96 samples with programmatically induced pores varying in nominal total porosity between 0% and 2% is tested: one half of the samples are prismatic, and the other half have a complex internal Triply Periodic Minimal Surface (TPMS) structure. In addition, a subset of the samples is scanned using X-ray micro-computed tomography (-CT). It is found that the resonance frequency corresponding to the 1 st compressional mode can predict the total nominal porosity even in TPMS samples. From statistical analysis, the smallest detectable porosity difference is found to be 0.25% for the prismatic samples and 0.5% for the TPMS samples. The experimental results agree well with the predictions of finite element (FE) simulations and analytical models. However, X-ray -CT appears to underestimate the porosity, possibly due to its inability to resolve the small pores. Our findings suggest that resonant ultrasonic testing can quantitatively assess the total porosity of AM parts having complex geometries.

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Review of Process–Structure–Property Relationships in Metals Fabricated Using Binder Jet Additive Manufacturing

Huang,

Cook,

Argüelles

et al. 2023

Metallogr. Microstruct. Anal.

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Uncovering microstructural heterogeneities in binder jet printed SS316L through ultrasonic testing and X-ray computed tomography

Cited by 8 publications

References 57 publications

Effect of the Particle Size Distribution of Irregular Al Powder on Properties of Parts for Electronics Fabricated by Binder Jetting

Effect of the Particle Size Distribution of Irregular Al Powder on Properties of Parts for Electronics Fabricated by Binder Jetting

Resonant Ultrasonic Testing can Quantitatively Assess the Microscopic Porosity of Complex-Shaped Additively Manufactured AlSi10Mg Components

Review of Process–Structure–Property Relationships in Metals Fabricated Using Binder Jet Additive Manufacturing

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