Abstract
As a non-beam-based additive manufacturing (AM) method, binder jet 3D printing (BJ3DP) is a process in which a liquid binder is jetted on layers of powdered materials, selectively joined, and then followed by densification process. Among AM technologies, binder jetting holds distinctive promise because of the possibility of rapid production of complex structures to achieve isotropic properties in the 3D printed samples. By taking advantage of traditional powder metallurgy, BJ3DP machines can produce prototypes in which material properties and surface finish are similar to those attained with traditional powder metallurgy. Various powdered materials have been 3D printed, but a typical challenge during BJ3DP is developing printing and post-processing methods that maximize part performance. Therefore, a detailed review of the physical processes during 3D printing and the fundamental science of densification after sintering and post–heat treatment steps are provided to understand the microstructural evolution and properties of binder jetted parts. Furthermore, to determine the effects of the binder jetting process on metallurgical properties, the role of powder characteristics (e.g., morphology, mean size, distribution), printing process parameters (e.g., layer thickness, print orientation, binder saturation, print speed, drying time), sintering (e.g., temperature, holding time), and post-processing are discussed. With the development of AM technologies and the need for post-processing in 3D printed parts, understanding the microstructural evolution during densification is necessary and here, processing steps are explained. Finally, opportunities for future advancement are addressed.
| Original language | English |
|---|---|
| Article number | 100707 |
| Journal | Progress in Materials Science |
| Volume | 119 |
| DOIs | |
| State | Published - Jun 2021 |
Funding
This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ). AM acknowledges startup funding from Mechanical, Materials and Aerospace Engineering Department at Illinois Institute of Technology at Chicago, Illinois. Further, AM thanks support from the postdoctoral research fellowship program of the Manufacturing Futures Initiative at Carnegie Mellon University (CMU).The authors would like to acknowledge Olivia Shafer’s assistance with formatting, editing, and constructive comments during preparation of this manuscript. AM and MC would like to acknowledge funding agencies supporting binder jet 3D printing studies at the University of Pittsburgh including partial funding by the Air Force Research Laboratory under agreement number FA8650-12-2-7230 , the Commonwealth of Pennsylvania, acting through the Pennsylvania Department of Community and Economic Development , under contract number C000053981 , and NSF award 1727676 (including REU supplements). FL and WT would like to thank the financial support from the National Science Foundation under grant CMMI-1752218 . This material is based upon work supported by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Office of Advanced Manufacturing, under contract number DE-AC05-00OR22725. The authors would also like to acknowledge the tremendous role of the reviewers and their valuable comments and suggestions that helped shape this manuscript.
| Funders | Funder number |
|---|---|
| Illinois Institute of Technology at Chicago | |
| Materials and Aerospace Engineering Department | |
| National Science Foundation | CMMI-1752218 |
| U.S. Department of Energy | |
| Directorate for Engineering | 1727676 |
| Pennsylvania Department of Community and Economic Development | C000053981 |
| Advanced Manufacturing Office | DE-AC05-00OR22725 |
| Office of Energy Efficiency and Renewable Energy | |
| Air Force Research Laboratory | FA8650-12-2-7230 |
| University of Pittsburgh | |
| Carnegie Mellon University |
Keywords
- Additive manufacturing
- Binder
- Ceramic
- Composite
- Indirect 3D printing
- Infiltration
- Materials selection
- Metal
- Post-processing
- Powder bed
- Powder characteristics
- Print processing parameters
- Sintering
