Metal Powder Recyclability in Binder Jet Additive Manufacturing
- PDF / 1,428,832 Bytes
- 10 Pages / 593.972 x 792 pts Page_size
- 41 Downloads / 254 Views
https://doi.org/10.1007/s11837-020-04258-6 Ó 2020 The Minerals, Metals & Materials Society
ORIGINAL PAPERADDITIVE MANUFACTURING: BEYOND THE BEAM TECHNOLOGY
Metal Powder Recyclability in Binder Jet Additive Manufacturing SAEREH MIRZABABAEI,1,2 BRIAN K. PAUL,1,2 and SOMAYEH PASEBANI 1,2,3 1.—School of Mechanical, Industrial and Manufacturing Engineering, Oregon State University, Corvallis, OR 97330, USA. 2.—Advanced Technology and Manufacturing Institute (ATAMI), Corvallis, OR 97330, USA. 3.—e-mail: [email protected]
The recyclability of 316L stainless steel powder in the binder jetting process has been determined. The powder characterization results demonstrated a 22% increase in the number of coarse particles (> 30 lm) and an 18.2% reduction in the number of small particles (< 10 lm) after recycling up to 16 times. A few elongated and irregular-shaped particles were found after recycling, possibly due to particle agglomeration during handling and sieving. A negligible increase in the oxygen content by 0.036% was detected in the recycled powder. The density of sintered parts produced using recycled powder was approximately 1.5% lower than when using fresh powder due to the changes in the particle size distribution and the flowability of the powder caused by the changes in morphology. Final parts built using fresh and recycled powder showed similar hardness (155 ± 3 HV and 165 ± 9 HV) and yield strength (206 ± 16 MPa and 192 ± 10 MPa), respectively.
INTRODUCTION Metal additive manufacturing (AM) is rapidly evolving from rapid prototyping into manufacturing of end-use products in various high-value sectors. AM enables the production of complex geometries in one step without the need for expensive tooling. Despite the revolutionary development of metal AM, its environmental effects have not been studied extensively. In powder bed processes, a considerable amount of metal powder is required to operate the machine, while only a small portion of it is used to build parts. The cost of powder for powder-based AM processes can range from 10% to 50% of the manufactured part cost for most alloys.1 Therefore, one cost-effective and environmentally driven approach to reducing powder consumption is powder recycling, thus enabling reuse of the same powder for multiple consecutive AM builds. The effect of the metal powder condition after recycling on the properties of the final part must be investigated to determine whether powder quality protocols are required. The characteristics of the powder determine the final density, mechanical properties, and performance of the additively manufactured parts.2 These include the morphology, chemistry, particle size distribution (PSD), powder bed density, flowability,
and spreadability. The powder manufacturing process determines the powder characteristics.1 Atomization is the most popular manufacturing process for powder for use in additive manufacturing and powder metallurgy.3 While water-atomized metallic powders are more common and cost effective in traditional press an
Data Loading...
