High-speed X-ray imaging of droplet-powder interaction in binder jet additive manufacturing

Lawrence, Jacob E.; Lawrence, Madi P.; Fezzaa, Kamel; Clark, Samuel J.; Crane, Nathan B.

doi:10.1016/j.addma.2024.104269

High-speed X-ray imaging of droplet-powder interaction in binder jet additive manufacturing

Journal Article · Tue Jun 18 00:00:00 EDT 2024 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2024.104269· OSTI ID:2569871

Lawrence, Jacob E. ^[1]; Lawrence, Madi P. ^[1]; Fezzaa, Kamel ^[2]; ^[2]; ^[1]

Brigham Young Univ., Provo, UT (United States)
Argonne National Laboratory (ANL), Argonne, IL (United States)

Binder jetting (BJ) is an additive manufacturing process that uses a powder feedstock in a layer wise process to print parts by selectively depositing a liquid binder into the powder bed using inkjet technology. This study presents findings from high-speed synchrotron imaging of binder droplet-interaction during the BJ printing process. A custom laboratory-scale BJ test platform was used for testing which enabled control of relevant process parameters including powder material, print geometry, spacing between droplets, powder bed density, and powder moisture content. Powder ejection was observed above the powder bed surface and powder relocation due to droplet impact was observed below the powder bed surface. Powder relocation was observed to be sensitive to powder material, powder bed density, powder bed moisture, droplet spacing, and print geometry. Increasing powder bed density was found to increase particle ejection velocity but reduce the total number of particles ejected. Process parameters that increase binder / moisture content in the powder bed were found to reduce powder ejection. The number of ejected powder particles was reduced for lower droplet spacings. Both powder ejection and powder relocation below the powder bed were reduced by treating the surface of the powder bed with a water/triethylene glycol (TEG) mixture before printing. In conclusion, results from this study help to build understanding of the physical mechanisms in the BJ printing process that may contribute to formation of defects observed in final parts.

View Accepted Manuscript (DOE)

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

Sponsoring Organization:: National Science Foundation (NSF); USDOE; USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities (SUF)

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 2569871

Alternate ID(s):: OSTI ID: 2407165

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Vol. 89; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (41)

Rewetting effects and droplet motion on partially wetted powder surfaces Hapgood, Karen P.; Nguyen, Thanh H.; Hauw, Sunarko AIChE Journal, Vol. 55, Issue 6 https://doi.org/10.1002/aic.11772	journal	June 2009
A regime map for granule formation by drop impact on powder beds Emady, Heather N.; Kayrak-Talay, Defne; Litster, James D. AIChE Journal, Vol. 59, Issue 1 https://doi.org/10.1002/aic.13952	journal	November 2012
Capillary Penetration of Liquid Droplets into Porous Materials Denesuk, M.; Smith, G. L.; Zelinski, B. J. J. Journal of Colloid and Interface Science, Vol. 158, Issue 1 https://doi.org/10.1006/jcis.1993.1235	journal	June 1993
Spreading and Infiltration of Inkjet-Printed Polymer Solution Droplets on a Porous Substrate Holman, Richard K.; Cima, Michael J.; Uhland, Scott A. Journal of Colloid and Interface Science, Vol. 249, Issue 2 https://doi.org/10.1006/jcis.2002.8225	journal	May 2002
Drop Penetration into Porous Powder Beds Hapgood, Karen P.; Litster, James D.; Biggs, Simon R. Journal of Colloid and Interface Science, Vol. 253, Issue 2 https://doi.org/10.1006/jcis.2002.8527	journal	September 2002
Effects of layer thickness and binder saturation level parameters on 3D printing process Vaezi, Mohammad; Chua, Chee Kai The International Journal of Advanced Manufacturing Technology, Vol. 53, Issue 1-4 https://doi.org/10.1007/s00170-010-2821-1	journal	July 2010
Absorption of millimeter- and micrometer-sized droplets on nylon powder Tan, Hua Experiments in Fluids, Vol. 63, Issue 12 https://doi.org/10.1007/s00348-022-03535-1	journal	December 2022
A versatile SPH modeling framework for coupled microfluid-powder dynamics in additive manufacturing: binder jetting, material jetting, directed energy deposition and powder bed fusion Fuchs, Sebastian L.; Praegla, Patrick M.; Cyron, Christian J. Engineering with Computers, Vol. 38, Issue 6 https://doi.org/10.1007/s00366-022-01724-4	journal	September 2022
Optimization of Binder Jetting Using Taguchi Method Shrestha, Sanjay; Manogharan, Guha JOM, Vol. 69, Issue 3 https://doi.org/10.1007/s11837-016-2231-4	journal	January 2017
Solid free-form fabrication of drug delivery devices Wu, Benjamin M.; Borland, Scott W.; Giordano, Russell A. Journal of Controlled Release, Vol. 40, Issue 1-2 https://doi.org/10.1016/0168-3659(95)00173-5	journal	June 1996
Three-Dimensional Printing: Rapid Tooling and Prototypes Directly from a CAD Model Sachs, E.; Cima, M.; Cornie, J. CIRP Annals, Vol. 39, Issue 1 https://doi.org/10.1016/S0007-8506(07)61035-X	journal	January 1990
Three-Dimensional Printing: The Physics and Implications of Additive Manufacturing Sachs, Emanuel; Cima, Michael; Cornie, James CIRP Annals - Manufacturing Technology, Vol. 42, Issue 1 https://doi.org/10.1016/S0007-8506(07)62438-X	journal	January 1993
High-fidelity modeling of binder–powder interactions in binder jetting: Binder flow and powder dynamics Yang, Zeshi; Zhang, Yanming; Yan, Wentao Acta Materialia, Vol. 260 https://doi.org/10.1016/j.actamat.2023.119298	journal	November 2023
High Speed Sintering: Assessing the influence of print density on microstructure and mechanical properties of nylon parts Ellis, Adam; Noble, Christopher J.; Hopkinson, Neil Additive Manufacturing, Vol. 1-4 https://doi.org/10.1016/j.addma.2014.07.003	journal	October 2014
Three-dimensional lattice Boltzmann simulations of high density ratio two-phase flows in porous media Sadeghi, R.; Shadloo, M. S.; Hopp-Hirschler, M. Computers & Mathematics with Applications, Vol. 75, Issue 7 https://doi.org/10.1016/j.camwa.2017.12.028	journal	April 2018
Drop penetration time in heterogeneous powder beds Nguyen, Thanh; Shen, Wei; Hapgood, Karen Chemical Engineering Science, Vol. 64, Issue 24 https://doi.org/10.1016/j.ces.2009.08.038	journal	December 2009
Three-dimensional simulation of micrometer-sized droplet impact and penetration into the powder bed Tan, Hua Chemical Engineering Science, Vol. 153 https://doi.org/10.1016/j.ces.2016.07.015	journal	October 2016
Process development toward full-density stainless steel parts with binder jetting printing Do, Truong; Kwon, Patrick; Shin, Chang Seop International Journal of Machine Tools and Manufacture, Vol. 121 https://doi.org/10.1016/j.ijmachtools.2017.04.006	journal	October 2017
A new physics-based model for equilibrium saturation determination in binder jetting additive manufacturing process Miyanaji, Hadi; Zhang, Shanshan; Yang, Li International Journal of Machine Tools and Manufacture, Vol. 124 https://doi.org/10.1016/j.ijmachtools.2017.09.001	journal	January 2018
Binder jet printing of tungsten heavy alloy Stawovy, Michael T.; Myers, Kyle; Ohm, Scott International Journal of Refractory Metals and Hard Materials, Vol. 83 https://doi.org/10.1016/j.ijrmhm.2019.104981	journal	September 2019
Impact of inkjet printing parameters and environmental conditions on formation of 2D and 3D binder jetting geometries Colton, Trenton; Inkley, Colton; Berry, Adam Journal of Manufacturing Processes, Vol. 71 https://doi.org/10.1016/j.jmapro.2021.09.024	journal	November 2021
Binder jetting additive manufacturing: Three-dimensional simulation of micro-meter droplet impact and penetration into powder bed Deng, Hongxin; Huang, Yanlu; Wu, Shibiao Journal of Manufacturing Processes, Vol. 74 https://doi.org/10.1016/j.jmapro.2021.12.019	journal	February 2022
Difference between powder bed density and green density for a free-flowing powder in binder jetting additive manufacturing Li, Ming; Miao, Guanxiong; Du, Wenchao Journal of Manufacturing Processes, Vol. 84 https://doi.org/10.1016/j.jmapro.2022.10.030	journal	December 2022
A process to spatially control the fraction of SS420 and bronze phases in binder jet infiltrated parts Salim, Nusrat Jahan; Arretche, Ignacio; Matlack, Kathryn H. Journal of Manufacturing Processes, Vol. 85 https://doi.org/10.1016/j.jmapro.2022.11.076	journal	January 2023
Critical influences of particle size and adhesion on the powder layer uniformity in metal additive manufacturing Meier, Christoph; Weissbach, Reimar; Weinberg, Johannes Journal of Materials Processing Technology, Vol. 266 https://doi.org/10.1016/j.jmatprotec.2018.10.037	journal	April 2019
Binder jet 3D printing—Process parameters, materials, properties, modeling, and challenges Mostafaei, Amir; Elliott, Amy M.; Barnes, John E. Progress in Materials Science https://doi.org/10.1016/j.pmatsci.2020.100707	journal	June 2020
Experimental study of liquid drop impact onto a powder surface Marston, J. O.; Thoroddsen, S. T.; Ng, W. K. Powder Technology, Vol. 203, Issue 2 https://doi.org/10.1016/j.powtec.2010.05.012	journal	November 2010
Granule formation mechanisms and morphology from single drop impact on powder beds Emady, Heather N.; Kayrak-Talay, Defne; Schwerin, William C. Powder Technology, Vol. 212, Issue 1 https://doi.org/10.1016/j.powtec.2011.04.030	journal	September 2011
Drop spreading and penetration into pre-wetted powders Marston, J. O.; Sprittles, J. E.; Zhu, Y. Powder Technology, Vol. 239 https://doi.org/10.1016/j.powtec.2013.01.062	journal	May 2013
Coordination number changes during powder densification German, Randall M. Powder Technology, Vol. 253 https://doi.org/10.1016/j.powtec.2013.12.006	journal	February 2014
Length and time scales of a liquid drop impact and penetration into a granular layer Katsuragi, Hiroaki Journal of Fluid Mechanics, Vol. 675 https://doi.org/10.1017/jfm.2011.31	journal	May 2011
Real time observation of binder jetting printing process using high-speed X-ray imaging Parab, Niranjan D.; Barnes, John E.; Zhao, Cang Scientific Reports, Vol. 9, Issue 1 https://doi.org/10.1038/s41598-019-38862-7	journal	February 2019
Wet granular materials Mitarai, Namiko; Nori, Franco Advances in Physics, Vol. 55, Issue 1-2 https://doi.org/10.1080/00018730600626065	journal	January 2006
Negative impact of humidity on the flowability of steel powders Marchetti, Lorenzo; Mellin, Pelle; Neil Hulme, Christopher Particulate Science and Technology, Vol. 40, Issue 6 https://doi.org/10.1080/02726351.2021.1995091	journal	November 2021
The Dynamics of Capillary Flow Washburn, Edward W. Physical Review, Vol. 17, Issue 3 https://doi.org/10.1103/PhysRev.17.273	journal	March 1921
Computer simulation of the packing of fine particles Yang, R. Y.; Zou, R. P.; Yu, A. B. Physical Review E, Vol. 62, Issue 3 https://doi.org/10.1103/PhysRevE.62.3900	journal	September 2000
Compensation of sintering deformation for components manufactured by metal binder jetting using numerical simulations Sadeghi Borujeni, Shahrooz; Saluja, Gursimran Singh; Ploshikhin, Vasily Rapid Prototyping Journal, Vol. 29, Issue 3 https://doi.org/10.1108/RPJ-06-2022-0181	journal	September 2022
Process parameters optimization for improving surface quality and manufacturing accuracy of binder jetting additive manufacturing process Chen, Han; Zhao, Yaoyao Fiona Rapid Prototyping Journal, Vol. 22, Issue 3 https://doi.org/10.1108/RPJ-11-2014-0149	journal	April 2016
An exploration of binder jetting of copper Bai, Yun; Williams, Christopher B. Rapid Prototyping Journal, Vol. 21, Issue 2 https://doi.org/10.1108/RPJ-12-2014-0180	journal	March 2015
Metal Binder Jetting Additive Manufacturing: A Literature Review Li, Ming; Du, Wenchao; Elwany, Alaa Journal of Manufacturing Science and Engineering, Vol. 142, Issue 9 https://doi.org/10.1115/1.4047430	journal	June 2020
A computational framework for modeling distortion during sintering of binder jet printed parts Paudel, Basil J.; Conover, Dave; Lee, Jung-Kun Journal of Micromechanics and Molecular Physics, Vol. 06, Issue 04 https://doi.org/10.1142/S242491302142008X	journal	December 2021

Similar Records

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

Journal Article · Sun May 21 20:00:00 EDT 2023 · Additive Manufacturing · OSTI ID:2423468

An in-situ crosslinking binder for binder jet additive manufacturing

Journal Article · Sun May 24 20:00:00 EDT 2020 · Additive Manufacturing · OSTI ID:1649053

Real time observation of binder jetting printing process using high-speed X-ray imaging

Journal Article · Wed Feb 20 19:00:00 EST 2019 · Scientific Reports · OSTI ID:1496827

Related Subjects

36 MATERIALS SCIENCE
Binder Jetting
Binder-Powder Interaction
Inkjet
SS316L
Synchrotron X-ray Imaging

High-speed X-ray imaging of droplet-powder interaction in binder jet additive manufacturing

Citation Formats

References (41)

Similar Records

Related Subjects