Packing fraction control during additive manufacturing of powder green bodies

Journal Article · 25 March 2025 · Powder Technology

DOI: https://doi.org/10.1016/j.powtec.2025.120968 · OSTI ID:2563670

Melchert, Drew S. ^[1]; Troksa, Michael ^[1]; DeOtte, Joshua ^[1]; Cahill, James T. ^[1]; Du Frane, Wyatt L. ^[1]; Kuntz, Joshua D. ^[1]

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1. Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

The demand for high performance ceramic and metal components with complex geometry necessitates developments in powder handling and green body shaping. Here, in this study, vibrational powder deposition is adapted to three-dimensional printing with the ability to modulate packing fraction during printing. Boron carbide powder with sub-micron primary particle size is printed over a packing fraction range of 25.0 % to 46.5 % (below the poured density to above the tapped density). Solid metal powders are printed at 67.5 %, which enables novel freestanding, vertical-walled features without binder. These capabilities introduce opportunities for more complex geometries in high-performance materials, e.g. large-scale uniaxial hot-pressing of ceramic ballistic armor components with graded thickness and three-dimensional curved or stepped features (by compensating for displacement differences during compaction). This technology also enables multi-material patterning of additive manufacturing powder beds with reduced feedstock quantity requirements and wastage.

• Research Organization: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
• Sponsoring Organization: USDOE National Nuclear Security Administration (NNSA)
• Grant/Contract Number: AC52-07NA27344
• OSTI ID: 2563670
• Report Number(s): LLNL--JRNL-867287; 1102142
• Journal Information: Powder Technology, Journal Name: Powder Technology Vol. 458; ISSN 0032-5910
• Publisher: ElsevierCopyright Statement
• Country of Publication: United States
• Language: English