Elsevier

Progress in Materials Science

Binder jet 3D printing—Procedure parameters, materials, backdrop, modeling, and challenges☆

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Open access

Abstract

Equally a non-axle-based additive manufacturing (AM) method, binder jet 3D printing (BJ3DP) is a process in which a liquid binder is jetted on layers of powdered materials, selectively joined, and and so followed by densification process. Amid AM technologies, binder jetting holds distinctive promise because of the possibility of rapid production of complex structures to attain isotropic properties in the 3D printed samples. By taking advantage of traditional pulverization metallurgy, BJ3DP machines tin can produce prototypes in which material properties and surface finish are similar to those attained with traditional powder metallurgy. Diverse powdered materials have been 3D printed, but a typical challenge during BJ3DP is developing press and mail service-processing methods that maximize part performance. Therefore, a detailed review of the physical processes during 3D press and the cardinal science of densification later on sintering and mail service–estrus treatment steps are provided to understand the microstructural development and properties of folder jetted parts. Furthermore, to determine the effects of the binder jetting process on metallurgical properties, the function of pulverization characteristics (due east.k., morphology, mean size, distribution), press process parameters (east.k., layer thickness, impress orientation, binder saturation, impress speed, drying time), sintering (e.g., temperature, belongings fourth dimension), and post-processing are discussed. With the development of AM technologies and the need for post-processing in 3D printed parts, understanding the microstructural evolution during densification is necessary and here, processing steps are explained. Finally, opportunities for future advocacy are addressed.

Keywords

Additive manufacturing

Indirect 3D printing

Sintering

Infiltration

Powder bed

Powder characteristics

Binder

Print processing parameters

Mail-processing

Materials choice

Metal

Ceramic

Composite

Cited by (0)

Dr. Amir Mostafaei is an Assistant Professor in the Department of Materials, Mechanical and Aerospace Engineering at the Illinois Institute of Applied science, Chicago, since January 2020, with a Ph.D. in Materials Science and Engineering science from the University of Pittsburgh, PA, United states of america, a post-medico research fellow at the Manufacturing Futures Initiatives (MFI) Center at Carnegie Mellon University between September 2018 and Dec 2019 and an M.Sc. degree in Corrosion and Materials Protection (Sahand Academy of Technology, Islamic republic of iran). His Ph.D. inquiry was main on binder jet 3D printing of structural, bio-compatible, metal matrix composites and magnetic shape retentiveness alloys. Effects of impress processing optimization during binder jetting also equally post-processing evolution including sintering and surface treatment of the 3D printed parts were investigated on the microstructural evolution, phase germination, and resulting properties of binder jetted parts.   Additionally, he has been working on laser powder bed fusion of metallic materials and evaluation of the processing parameters on the microstructure, porosity distribution, mechanical properties, and corrosion behavior of various additive manufactured parts from titanium, aluminum, stainless steel, and nickel-based alloys. Dr. Mostafaei has published literature in loftier temperature corrosion and failure analysis of stainless steels and nickel-based superalloys used in petroleum and nuclear power plants, multi-functional organic coatings, welding metallurgy, and nanomaterials fabrication. Finally,   Dr. Mostafaei's research mainly focuses on applying primal   aspects of materials science and engineering to accost the demands of various manufacturing industries via additive manufacturing.

Dr. Amy Elliott got her BS from Tennessee Technological University and her Ph.D. is from Virginia Polytechnic and State University, both Mechanical Technology. She served as the PI for Folder Jet Additive Manufacturing at Oak Ridge National Laboratory's Manufacturing Demonstration Facility (MDF) since 2014, leading over $4M in research in printed metallic powder densification, modeling, and printing along with binder evolution. Equally part of her role at the MDF, Dr. Elliott meets with people in industry around the world to consult on the proper application of folder jetting engineering science in manufacturing. Dr. Elliott'southward current areas of focus include materials development for folder jetting of oestrus exchangers in harsh environments, binder development for metallic powders, computational modeling of sintering distortion, and development of new metallic matrix and ceramic matrix composites for utilise in mining and fossil extraction, heat commutation, armor, and neutron collimation.

Dr. John Barnes is the Founder of The Barnes Group Advisors and was Vice President of Advanced Manufacturing & Strategy at Arconic, where he worked with Airbus to authorize the outset titanium additively manufactured parts for series production on the A350. Prior to Arconic, he was Managing director of the High-Operation Metals Program for the CSIRO, the national science agency for Australia where he oversaw the R&D and commercialization activities and investments in the plan's 2 principal areas: metal production and condiment manufacturing. His aerospace background includes lengthy positions at Honeywell Engines, where he supported gas turbine avant-garde engineering science and was plan manager of Marine Engines programs and every bit senior managing director for Manufacturing Exploration and Development at Lockheed Martin Skunk Works. At Lockheed Martin, he was responsible for developments in avant-garde polymers, composites, carbon nanotubes, novel titanium product and processing, additive manufacturing of both polymer and metal systems, and depression observable manufacturing methods. John has 12 patents issued or awaiting and has given numerous invited presentations is published internationally. In 2014, he was awarded Purdue Academy's Outstanding Materials Engineer of the Year and was given an Adjunct professorship at RMIT. In 2017, the kinesthesia of Carnegie Mellon Academy appointed him an Adjunct Professor of Materials Engineering science. John holds a BS in materials science and applied science and an MS in metallurgical engineering from Purdue University.

Fangzhou Li is a PhD student in the Department of Mechanical Applied science at the Academy of Utah. He currently works in the Laboratory of Laser-based Manufacturing and focuses his inquiry on the computational fluid dynamics and fluid-structure interaction in diverse additive manufacturing process, including folder jetting, laser powder bed fusion, and directed free energy degradation. Prior to this, he worked in the Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures from 2016 to 2018, where he investigated the process-microstructure-property relationship in the novel metallic bump-assisted resistance spot welding and the magnetic assisted resistance spot welding technologies. He received his BS and MS degrees in mechanical applied science from Shanghai Jiao Tong University.

Dr. Wenda Tan is an assistant professor in the Department of Mechanical Engineering at the University of Utah. He is also the managing director of the Laboratory of Laser-based Manufacturing. His major expertise lies in the areas of computational estrus transfer, computational fluid mechanics, and computational materials. He takes reward of such expertise to investigate the fundamental science regarding the process-microstructure-property relationship in diverse manufacturing processes, such as additive manufacturing, welding and joining, and casting. He received his BS and MS degrees in Mechanical Engineering from Tsinghua University, China, and his PhD degree in Mechanical Engineering from Purdue Academy. He also received the prestigious CAREER award of National Scientific discipline Foundation in 2018.

Dr. Corson L. Cramer went to Michigan Technological University for my BS in mechanical applied science and Colorado State University for G.Sc. and Ph.D. in mechanical engineering. He is a post-doctoral research associate in the Folder Jet Additive Manufacturing Team at Oak Ridge National Laboratory's (ORNL) Manufacturing Demonstration Facility since 2017, where he has led projects on ceramics, ceramic composites, and metallic-ceramic composites. He has published literature in pulverisation processing, thin-motion picture processing, ceramics, semiconductors, and thermoelectrics. He has several patent disclosures filed since working at ORNL. Dr. Cramer's electric current areas of research include ceramic and composite materials evolution for binder jetting, development of new metal-matrix and ceramic-matrix composites, processing of ceramics, and novel processing and press of ceramic materials. He is a member of SME and ACERS.

Dr. Peeyush Nandwana got his Bachelor of Engineering science at Visvesvaraya National Institute of Engineering, India (Metallurgical and Materials Science and Engineering), K.Sc. and Ph.D. at the University of North Texas (Materials Science and Engineering). He is a enquiry staff member at Oak Ridge National Laboratory'south Manufacturing Sit-in Facility since 2014. He has worked on diverse additive manufacturing technologies such as powder bed electron beam melting, laser powder bed fusion, laser wire deposition, and binder jet additive manufacturing of various materials such every bit titanium alloys, nickel-based superalloys, and steels. Dr. Nandwana leads the effort on densification of tool steels and other monolithic alloys deposited via binder jet condiment manufacturing with a focus on materials label and mechanical behavior. Furthermore, Dr. Nandwana leads the effort on developing hot isostatic pressing cycles for additive manufacturing materials to improve mechanical properties such equally fatigue strength for these materials. Dr. Nandwana's research focuses on applying materials science fundamentals to accost the demands of various manufacturing industries via additive manufacturing.

Dr. Markus Chmielus is an associate professor in the Mechanical Engineering and Materials Science Department since September 2013, with a PhD in materials science and engineering science from the Technical University of Berlin and the Helmholtz Center for Materials and Energy, Frg, a post-doc at Cornell University (2010 to 2013) and MS degrees in aerospace engineering (University of Stuttgart, Germany) and materials science and engineering (Boise Country University). Dr. Chmielus'due south Advanced Manufacturing and Magnetic Materials Laboratory performs research on functional and structural metals on the influence of production and processing parameters on the properties and microstructure. The lab focuses on additive manufacturing of metals and peculiarly folder jet printing and the influence of postal service-processing on microstructural evolution and properties. The second   research surface area is fundamental research, manufacturing, and applications of functional, magnetic materials such as Ni-Mn-Ga magnetic shape-memory alloys and magnetocaloric materials, especially the attribute of using condiment manufacturing every bit a new artery to produce these materials. A master interest is the understanding of microstructural development during printing and post-processing and how different additive manufacturing methods and processing affect the functional properties of functional magnetic materials. The overarching umbrella of all inquiry activities is quantitative characterization of microstructure, defects, mechanical, electrical, magnetic, and thermal properties on different length scales using local, national, and international facilities, including synchrotron and neutron diffraction and collaborations.

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