Impact of controlled prewetting on part formation in binder jet additive manufacturing

Inkley, Colton G.; Lawrence, Jacob E.; Crane, Nathan B.

doi:10.1016/j.addma.2023.103619

Impact of controlled prewetting on part formation in binder jet additive manufacturing

Journal Article · Mon May 22 00:00:00 EDT 2023 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2023.103619· OSTI ID:2423468

Inkley, Colton G. ^[1]; ^[1]; Crane, Nathan B. ^[1]

Brigham Young Univ., Provo, UT (United States)

Binder jetting is an additive manufacturing process that bonds powder through selectively depositing binder by inkjet printing. The part is then extracted and densified by sintering and/or infiltration. The process offers low costs and fast build rates, but properties can be poor due to residual porosity after sintering. The inkjet printing process may contribute to this residual porosity by creating large pores. The droplet kinetic energy ejects some powder particles from the bed and rearranges others. Particle ejection and rearrangement are theorized to create porous regions in binder-jetted parts. In this work, small amounts of moisture are added to the spread powder before printing and the impact on part formation, part properties, and printing parameters measured with varied droplet spacing, droplet velocity, and print frequency. Moisture is added by applying an atomized fluid mixture to the powder between layer spreading and binder printing. The fluid mixture partially evaporates but leaves a stable residue to increase cohesion and enhance imbibition. Moisture addition to the powder increases the range of droplet spacings for line formation while reducing particle ejection, powder rearrangement, and balling in layer and multilayer parts. Excessive moisture addition decreases the effective saturation of printed lines, but saturation in 3D parts is less impacted. Increased surface roughness in the first few layers of a print was also mitigated with prewetting. Finally, high-speed X-ray imaging verified prewetting reduction in particle ejection and rearrangement.

View Accepted Manuscript (DOE)

Research Organization:: Argonne National Laboratory (ANL), Argonne, IL (United States). Advanced Photon Source (APS)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 2423468

Alternate ID(s):: OSTI ID: 1975411

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Vol. 72; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Related Subjects

36 MATERIALS SCIENCE
Binder jetting
Engineering
Ink jet
Materials Science
Porosity
Prewetting
Saturation
Surface roughness
Synchrotron X-ray imaging

Impact of controlled prewetting on part formation in binder jet additive manufacturing

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References (43)

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