Additive Manufacturing of Ceramic-based Materials: Process Development, Materials, Process Optimization and Applications: Poster Session
Sponsored by: ACerS Engineering Ceramics Division, ACerS Basic Science Division, TMS: Additive Manufacturing Committee, TMS: Computational Materials Science and Engineering Committee
Program Organizers: Lei Chen, University of Michigan-Dearborn; Xuan Song, University of Iowa; Nahum Travitzky, University of Erlangen-Nuremberg; Yiquan Wu, Alfred University; Paolo Colombo, University of Padova; Rajendra Bordia, Clemson University; Long-Qing Chen, Pennsylvania State University
Tuesday 4:45 PM
November 3, 2020
Room: Poster Hall
Location: MS&T Virtual
Effects of Printing Parameters on Density And Mechanical Properties of Binder Jet 3D Printed WC-Co: Katerina Kimes1; Pierangeli Rodriguiz1; Danielle Brunetta1; Drew Elhassid2; Markus Chmielus1; 1University of Pittsburgh; 2General Carbide
Tungsten carbide-cobalt (WC-Co) is a cermet with excellent combination of hardness, provided by WC grains, and toughness, provided by the Co-matrix. Traditionally, WC-Co parts are formed through powder metallurgy. WC and Co powders are pressed to a low-density part, which is de-waxed, sintered and hot-isostatic-pressed (HIP). However, this demands mass production to justify mold creation, resulting in a slow and expensive process. Additive Manufacturing, particularly binder jet 3D-printing (BJ3DP) appeared as an option to supplement traditional WC-Co manufacturing, allowing the production of fast and detailed parts. A design of experiments was schemed to find the optimal printing parameters to form parts with high green densities, translating to high hardness and toughness. The highest green densities were obtained with a 220% binder saturation, 45 s drying time, 100 µm layer thickness, 5 mm/s roller speed, and a build-to-feed ratio of 2. Sintered-HIPed parts resulted in 99% density and 1286 HV hardness.
Hybrid Additive Manufacturing Technology Applied to Si3N4 Freeform Components Fabrication: Anna De Marzi1; Johanna Schmidt2; Sarah Diener3; Giorgia Franchin1; Paolo Colombo1; 1Department of Industrial Engineering, Università degli Studi di Padova; 2Schunk GmbH; 3Kyocera Fineceramics Precision GmbH
DIW and Vat Photo-polymerization techniques have been largely developed in the past years. Their use is however limited due to the process of material consolidation itself. In order to overcome their drawbacks, the two technologies will be combined so just a thin shell of the extruded filament will need to be consolidated to maintain itself. Therefore, it’s possible to not tune the ink’s rheology is required and to deal with black ceramic particles. A suspension of silicon nitride powder in an acrylate mixture will be printed in different freeforming shapes by using a prototyped system composed of an UV LEDs array mounted over the printer head of a DIW equipment and controlled via the machine gcode path. The hybrid equipment will be shown and presented. Debinding and sintering processes were performed to remove the organic part of the structure and SEM images were taken to determine its densification.
Temporary Coating for Binder Jet 3D Printed Tungsten Carbide-Cobalt Parts: Pierangeli Rodriguez De Vecchis1; Katerina Kimes1; Drew Elhassid2; Markus Chmielus1; 1University of Pittsburgh; 2General Carbide
Tungsten carbide-cobalt (WC-Co) is a cermet material with excellent mechanical properties provided by small WC grains in a Co-matrix. Traditionally, WC-Co parts are formed through powder injection molding (slow, expensive and restricted to mass production). Binder jet 3D printing (BJ3DP) appeared as an alternative to traditional WC-Co manufacturing, allowing the production of highly detailed parts. Printing parameters for this complex powder were selected through a Design of Experiments. Previous studies showed storage and transportation of green parts induced cracks before sintering. This project aimed to find a temporary coating to facilitate transportation of green parts. ExOne solvent binder 04 and low-viscosity Cerita 983 runner wax (Paramelt Inc.) were compared. Mainly through microstructural analysis (grain size, squareness, phases and defects present), density and hardness results, the binder-coating was chosen to be the best option as it improved edge retention and mechanical properties of the part without significantly damaging the microstructure.