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

Lee, Yousub; Nandwana, Peeyush; Simunovic, Srdjan

doi:10.1007/s40964-021-00214-1

Title: 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

^[1];

^[1]

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)

Cite

Export

Save

Research Organization:: Oak Ridge National Lab. (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, Vol. 1, Issue 1; ISSN 2363-9512

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

References (37)

Effect of Particle Size Distribution on Powder Packing and Sintering in Binder Jetting Additive Manufacturing of Metals Bai, Yun; Wagner, Grady; Williams, Christopher B. Journal of Manufacturing Science and Engineering, Vol. 139, Issue 8 https://doi.org/10.1115/1.4036640	journal	June 2017
Dimensional and geometrical precision of parts produced by binder jetting process as affected by the anisotropic shrinkage on sintering Zago, Marco; Lecis, Nora Francesca Maria; Vedani, Maurizio Additive Manufacturing, Vol. 43 https://doi.org/10.1016/j.addma.2021.102007	journal	July 2021
Powder-spreading mechanisms in powder-bed-based additive manufacturing: Experiments and computational modeling Chen, Hui; Wei, Qingsong; Zhang, Yingjie Acta Materialia, Vol. 179 https://doi.org/10.1016/j.actamat.2019.08.030	journal	October 2019
Optimisation of blade type spreaders for powder bed preparation in Additive Manufacturing using DEM simulations Haeri, S. Powder Technology, Vol. 321 https://doi.org/10.1016/j.powtec.2017.08.011	journal	November 2017
Sinter structure analysis of titanium structures fabricated via binder jetting additive manufacturing Wheat, Evan; Vlasea, Mihaela; Hinebaugh, James Materials & Design, Vol. 156 https://doi.org/10.1016/j.matdes.2018.06.038	journal	October 2018
Powder bed binder jet 3D printing of Inconel 718: Densification, microstructural evolution and challenges☆ Nandwana, Peeyush; Elliott, Amy M.; Siddel, Derek Current Opinion in Solid State and Materials Science, Vol. 21, Issue 4 https://doi.org/10.1016/j.cossms.2016.12.002	journal	August 2017
Dynamic simulation of powder packing structure for powder bed additive manufacturing Lee, Y. S.; Nandwana, P.; Zhang, W. The International Journal of Advanced Manufacturing Technology, Vol. 96, Issue 1-4 https://doi.org/10.1007/s00170-018-1697-3	journal	February 2018
Modeling and characterization of cohesion in fine metal powders with a focus on additive manufacturing process simulations Meier, Christoph; Weissbach, Reimar; Weinberg, Johannes Powder Technology, Vol. 343 https://doi.org/10.1016/j.powtec.2018.11.072	journal	February 2019
Powder metallurgy of titanium – past, present, and future Fang, Zhigang Zak; Paramore, James D.; Sun, Pei International Materials Reviews, Vol. 63, Issue 7 https://doi.org/10.1080/09506608.2017.1366003	journal	August 2017
Process development for green part printing using binder jetting additive manufacturing Miyanaji, Hadi; Orth, Morgan; Akbar, Junaid Muhammad Frontiers of Mechanical Engineering, Vol. 13, Issue 4 https://doi.org/10.1007/s11465-018-0508-8	journal	May 2018
Influence of Powder Bed Characteristics on Material Quality in Additive Manufacturing Zielinski, Jonas; Vervoort, Simon; Mindt, Hans-Wilfried BHM Berg- und Hüttenmännische Monatshefte, Vol. 162, Issue 5 https://doi.org/10.1007/s00501-017-0592-9	journal	March 2017
Micromechanical modelling of viscous sintering and a constitutive equation with sintering stress Shinagawa, K. Computational Materials Science, Vol. 13, Issue 4 https://doi.org/10.1016/S0927-0256(98)00132-3	journal	January 1999
Current understanding and future research directions at the onset of the next century of sintering science and technology Bordia, Rajendra K.; Kang, Suk-Joong L.; Olevsky, Eugene A. Journal of the American Ceramic Society, Vol. 100, Issue 6 https://doi.org/10.1111/jace.14919	journal	May 2017
Multi-Scale Study of Sintering: A Review Olevsky, Eugene A.; Tikare, Veena; Garino, Terry Journal of the American Ceramic Society, Vol. 89, Issue 6 https://doi.org/10.1111/j.1551-2916.2006.01054.x	journal	June 2006
Microstructure evolution during binder jet additive manufacturing of H13 tool steel Nandwana, Peeyush; Kannan, Rangasayee; Siddel, Derek Additive Manufacturing, Vol. 36 https://doi.org/10.1016/j.addma.2020.101534	journal	December 2020
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
Modeling the evolution of lithium-ion particle contact distributions using a fabric tensor approach Stershic, A. J.; Simunovic, S.; Nanda, J. Journal of Power Sources, Vol. 297 https://doi.org/10.1016/j.jpowsour.2015.07.088	journal	November 2015
Revealing particle-scale powder spreading dynamics in powder-bed-based additive manufacturing process by high-speed x-ray imaging Escano, Luis I.; Parab, Niranjan D.; Xiong, Lianghua Scientific Reports, Vol. 8, Issue 1 https://doi.org/10.1038/s41598-018-33376-0	journal	October 2018
Powder Bed Layer Characteristics: The Overseen First-Order Process Input Mindt, H. W.; Megahed, M.; Lavery, N. P. Metallurgical and Materials Transactions A, Vol. 47, Issue 8 https://doi.org/10.1007/s11661-016-3470-2	journal	April 2016
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
Discrete element simulation and experimental study of powder spreading process in additive manufacturing Haeri, S.; Wang, Y.; Ghita, O. Powder Technology, Vol. 306 https://doi.org/10.1016/j.powtec.2016.11.002	journal	January 2017
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
Discrete element simulation of powder layer thickness in laser additive manufacturing Han, Quanquan; Gu, Heng; Setchi, Rossitza Powder Technology, Vol. 352 https://doi.org/10.1016/j.powtec.2019.04.057	journal	June 2019
Effect of powder size distribution on densification and microstructural evolution of binder-jet 3D-printed alloy 625 Mostafaei, Amir; Rodriguez De Vecchis, Pierangeli; Nettleship, Ian Materials & Design, Vol. 162 https://doi.org/10.1016/j.matdes.2018.11.051	journal	January 2019
Finite element simulation of hot isostatic pressing of metal powders Abouaf, M.; Chenot, J. L.; Raisson, G. International Journal for Numerical Methods in Engineering, Vol. 25, Issue 1 https://doi.org/10.1002/nme.1620250116	journal	January 1988
Models, algorithms and validation for opensource DEM and CFD-DEM Kloss, Christoph; Goniva, Christoph; Hager, Alice Progress in Computational Fluid Dynamics, An International Journal, Vol. 12, Issue 2/3 https://doi.org/10.1504/PCFD.2012.047457	journal	January 2012
Theory of sintering: from discrete to continuum Olevsky, Eugene A. Materials Science and Engineering: R: Reports, Vol. 23, Issue 2 https://doi.org/10.1016/S0927-796X(98)00009-6	journal	June 1998
Dynamic investigation on the powder spreading during selective laser melting additive manufacturing Yao, Dengzhi; An, Xizhong; Fu, Haitao Additive Manufacturing, Vol. 37 https://doi.org/10.1016/j.addma.2020.101707	journal	January 2021
Particle-based simulation of powder application in additive manufacturing Parteli, Eric J. R.; Pöschel, Thorsten Powder Technology, Vol. 288 https://doi.org/10.1016/j.powtec.2015.10.035	journal	January 2016
Verification, Performance, Validation, and Modifications to the SOVS Continuum Constitutive Model in a Nonlinear Large-Deformation Finite Element Code Argüello, José Guadalupe; Reiterer, Markus W.; Ewsuk, Kevin G. Journal of the American Ceramic Society, Vol. 92, Issue 7 https://doi.org/10.1111/j.1551-2916.2009.03008.x	journal	July 2009
A comparative study of different sintering models for Al₂O₃ Van Nguyen, Chung; Sistla, Sree Koundinya; Van Kempen, Stanley Journal of the Ceramic Society of Japan, Vol. 124, Issue 4 https://doi.org/10.2109/jcersj2.15257	journal	January 2016
Influences of Powder Compaction Constitutive Models on the Finite Element Simulation of Hot Isostatic Pressing Abdelhafeez, A. M.; Essa, K. E. A. Procedia CIRP, Vol. 55 https://doi.org/10.1016/j.procir.2016.07.025	journal	January 2016
Binder jetting additive manufacturing of 420 stainless steel: Densification during sintering and effect of heat treatment on microstructure and hardness Sufiiarov, Vadim; Polozov, Igor; Kantykov, Artem Materials Today: Proceedings, Vol. 30 https://doi.org/10.1016/j.matpr.2020.01.144	journal	January 2020
Multiscale modeling of pressure-assisted sintering Nosewicz, S.; Rojek, J.; Wawrzyk, K. Computational Materials Science, Vol. 156 https://doi.org/10.1016/j.commatsci.2018.10.001	journal	January 2019
Effect of Particle Spreading Dynamics on Powder Bed Quality in Metal Additive Manufacturing Lee, Yousub; Gurnon, A. Kate; Bodner, David Integrating Materials and Manufacturing Innovation, Vol. 9, Issue 4 https://doi.org/10.1007/s40192-020-00193-1	journal	November 2020
Multi-scale modeling of shape distortions during sintering of bi-layers Molla, Tesfaye Tadesse; Bjørk, Rasmus; Olevsky, Eugene Computational Materials Science, Vol. 88 https://doi.org/10.1016/j.commatsci.2014.02.041	journal	June 2014
A Comprehensive Approach to Powder Feedstock Characterization for Powder Bed Fusion Additive Manufacturing: A Case Study on AlSi7Mg Muñiz-Lerma, Jose; Nommeots-Nomm, Amy; Waters, Kristian Materials, Vol. 11, Issue 12 https://doi.org/10.3390/ma11122386	journal	November 2018

Similar Records

Infiltration of Nanoparticles into Porous Binder Jet Printed Parts

Journal Article · Fri Jan 01 00:00:00 EST 2016 · American Journal of Engineering and Applied Sciences · OSTI ID:1813263

Elliott, Amelia; AlSalihi, Sarah; Merriman, Abbey L.; +1 more

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

Journal Article · Tue Jan 03 00:00:00 EST 2017 · Current Opinion in Solid State and Materials Science · OSTI ID:1813263

Nandwana, Peeyush; Elliott, Amy M.; Siddel, Derek; +3 more

PRELIMINARY TESTING OF NANOPARTICLE EFFECTIVENESS IN BINDER JETTING APPLICATIONS

Conference · Fri Jan 01 00:00:00 EST 2016 · OSTI ID:1813263

Bailey, Alta C; Elliott, Amy M; Basti, Mufeed M

Related Subjects

36 MATERIALS SCIENCE
Binder jetting
Additive manufacturing
Powder spreading
Sintering deformation
Discrete element method
Finite element method
Particle segregation

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

Citation Formats

References (37)

Similar Records

Related Subjects