Powder bed binder jet 3D printing of Inconel 718: Densification, microstructural evolution and challenges

Nandwana, Peeyush; Elliott, Amy M.; Siddel, Derek; Merriman, Abbey; Peter, William H.; Babu, Sudarsanam S.

doi:10.1016/j.cossms.2016.12.002

Title: Powder bed binder jet 3D printing of Inconel 718: Densification, microstructural evolution and challenges

Journal Article · Tue Jan 03 00:00:00 EST 2017 · Current Opinion in Solid State and Materials Science

DOI:https://doi.org/10.1016/j.cossms.2016.12.002· OSTI ID:1339381

Nandwana, Peeyush ^[1]; Elliott, Amy M. ^[2]; Siddel, Derek ^[3]; Merriman, Abbey ^[3]; Peter, William H. ^[2]; Babu, Sudarsanam S. ^[4]

Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Materials Science and Technology Division and Manufacturing Demonstration Facility
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility and Energy and Transportation Sciences Division
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility and Energy and Transportation Sciences Division ; Univ. of Tennessee, Knoxville, TN (United States). Department of Mechanical, Aerospace and Biomedical Engineering

Traditional manufacturing of Inconel 718 components from castings and thermomechanical processing routes involve extensive post processing and machining to attain the desired geometry. Additive manufacturing (AM) technologies including direct energy deposition (DED), selective laser melting (SLM), electron beam melting (EBM) and binder jet 3D printing (BJ3DP) can minimize scrap generation and reduce lead times. While there is extensive literature on the use of melting and solidification based AM technologies, there has been limited research on the use of binder jet 3D printing. In this paper, a brief review on binder jet additive manufacturing of Inconel 718 is presented. In addition, existing knowledge on sintering of Inconel 718 has been extended to binder jet 3D printing. We found that supersolidus liquid phase sintering (SLPS) is necessary to achieve full densification of Inconel 718. SLPS is sensitive to the feedstock chemistry that has a strong influence on the liquid volume fraction at the processing temperature. Based on these results, we discuss an empirical framework to determine the role of powder particle size and liquid volume fraction on sintering kinetics. In conclusion, the role of powder packing factor and binder saturation on microstructural evolution is discussed. The current challenges in the use of BJ3DP for fabrication of Inconel 718, as well as, extension to other metal systems, are presented.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). High Temperature Materials Lab. (HTML); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1339381

Alternate ID(s):: OSTI ID: 1550649

Journal Information:: Current Opinion in Solid State and Materials Science, Vol. 21, Issue 4; ISSN 1359-0286

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 103 works

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36 MATERIALS SCIENCE
Powder bed
Additive manufacturing
Binder jet 3D printing
Supersolidus liquid phase sintering
Solid-state sintering
Powder feedstock
Powder size distribution
Inconel 718
Microstructure

Title: Powder bed binder jet 3D printing of Inconel 718: Densification, microstructural evolution and challenges

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