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

Abstract

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 ofmore » BJ3DP for fabrication of Inconel 718, as well as, extension to other metal systems, are presented.« less

Authors:

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

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+ Show Author Affiliations

1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Materials Science and Technology Division and Manufacturing Demonstration Facility
2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility and Energy and Transportation Sciences Division
3. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility
4. 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

Publication Date:

Tue Jan 03 00:00:00 EST 2017

Research Org.:

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 Org.:

USDOE Office of Energy Efficiency and Renewable Energy (EERE)

OSTI Identifier:

1339381

Alternate Identifier(s):

OSTI ID: 1550649

Grant/Contract Number:  

AC05-00OR22725

Resource Type:

Accepted Manuscript

Journal Name:

Current Opinion in Solid State and Materials Science

Additional Journal Information:

Journal Volume: 21; Journal Issue: 4; Journal ID: ISSN 1359-0286

Publisher:

Elsevier

Country of Publication:

United States

Language:

English

Subject:

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