Powder spreading, densification, and part deformation in binder jetting additive manufacturing

Lee, Yousub; Nandwana, Peeyush; Simunovic, Srdjan

doi:10.1007/s40964-021-00214-1

Powder spreading, densification, and part deformation in binder jetting additive manufacturing

Journal Article · Tue Jul 27 00:00:00 EDT 2021 · Progress in Additive Manufacturing

DOI:https://doi.org/10.1007/s40964-021-00214-1· OSTI ID:1813263

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Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Binder jetting additive manufacturing (AM) can print complex structures in economical and scalable manner. Binder jetting AM comprises of deposition and weak binding of particles, known as green part, at room temperature and subsequent binder removal and sintering densification at high temperatures. However, during the densification (i.e., sintering), the part significantly deforms due to volume shrinkage. The deformation during sintering is difficult to predict, which prevents the widespread application of this technology. In this research, powder spreading simulation using discrete element method (DEM) was performed first to capture local variations in powder bed configuration. Second, finite element method (FEM) with a phenomenological continuum constitutive model was used to predict part shrinkage during the sintering process. DEM simulation showed variations in packing density, particle segregation, formation of uneven powder bed surface, and shift in particle size distribution (PSD). The sintering simulation modeled part deformation with a reasonable accuracy of 3% for solid-state sintering and intermediate liquid phase sintering. A demonstration case with non-uniform initial packing density showed that inhomogeneous green part density and PSD should be accounted for prediction of part deformation in binder jetting AM.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

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

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1813263

Journal Information:: Progress in Additive Manufacturing, Journal Name: Progress in Additive Manufacturing Journal Issue: 1 Vol. 1; ISSN 2363-9512

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

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