Articoli di riviste: "Metal extrusion additive manufacturing"

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Langelandsvik, Geir, Magnus Eriksson, Odd M. Akselsen e Hans J. Roven. "Wire arc additive manufacturing of AA5183 with TiC nanoparticles". International Journal of Advanced Manufacturing Technology 119, n. 1-2 (13 novembre 2021): 1047–58. http://dx.doi.org/10.1007/s00170-021-08287-6.

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AbstractAluminium alloys processed by wire arc additive manufacturing (WAAM) exhibit a relatively coarse microstructure with a columnar morphology. A powerful measure to refine the microstructure and to enhance mechanical properties is to promote grain refinement during solidification. Addition of ceramic nanoparticles has shown great potential as grain refiner and strengthening phase in aluminium alloys. Thus, an Al-Mg alloy mixed with TiC nanoparticles was manufactured by the novel metal screw extrusion method to a wire and subsequently deposited by WAAM. Measures to restrict oxidation of magnesium during metal screw extrusion were examined. Purging of CO2 gas into the extrusion chamber resulted in a remarkable reduction in formation of MgO and Mg(OH)2. TiC decomposed to Al3Ti during WAAM deposition, leading to a significant grain refinement of 93% compared to a commercial benchmark. The presence of remaining TiC nanoparticles accounted for an increased hardness of the WAAM material through thermal expansion mismatch strengthening and Orowan strengthening. Exposure of TiC to moisture in air during metal screw extrusion increased the internal hydrogen content significantly, and a highly porous structure was seen after WAAM deposition.

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Costa, José, Elsa Sequeiros, Maria Teresa Vieira e Manuel Vieira. "Additive Manufacturing". U.Porto Journal of Engineering 7, n. 3 (30 aprile 2021): 53–69. http://dx.doi.org/10.24840/2183-6493_007.003_0005.

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Additive manufacturing (AM) is one of the most trending technologies nowadays, and it has the potential to become one of the most disruptive technologies for manufacturing. Academia and industry pay attention to AM because it enables a wide range of new possibilities for design freedom, complex parts production, components, mass personalization, and process improvement. The material extrusion (ME) AM technology for metallic materials is becoming relevant and equivalent to other AM techniques, like laser powder bed fusion. Although ME cannot overpass some limitations, compared with other AM technologies, it enables smaller overall costs and initial investment, more straightforward equipment parametrization, and production flexibility.This study aims to evaluate components produced by ME, or Fused Filament Fabrication (FFF), with different materials: Inconel 625, H13 SAE, and 17-4PH. The microstructure and mechanical characteristics of manufactured parts were evaluated, confirming the process effectiveness and revealing that this is an alternative for metal-based AM.

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Fabrizio, Matteo, Matteo Strano, Daniele Farioli e Hermes Giberti. "Extrusion Additive Manufacturing of PEI Pellets". Journal of Manufacturing and Materials Processing 6, n. 6 (8 dicembre 2022): 157. http://dx.doi.org/10.3390/jmmp6060157.

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The simplest, most cost-efficient, and most widespread Additive Manufacturing (AM) technology is Extrusion Additive Manufacturing (EAM). Usually, EAM is performed with filament feedstock, but using pellets instead of filaments yields many benefits, including significantly lower cost and a wider choice of materials. High-performance polymers offer high strength even when produced with AM technique, allowing to produce near-net-shape functional parts. The production of these materials in filament form is still limited and expensive; therefore, in this paper, the possibility of producing AM components with engineering polymers from pellets will be thoroughly investigated. In this work, the effectiveness of a specially designed AM machine for printing high-performance materials in pellet form was tested. The material chosen for the investigation is PEI 1000 which offers outstanding mechanical and thermal properties, giving the possibility to produce with EAM functional components. Sensitivity analyses have been carried out to define a process window in terms of thermal process parameters by observing different response variables. Using the process parameters in the specified range, the additive manufactured material has been mechanically tested, and its microstructure has been investigated, both in dried and undried conditions. Finally, a rapid tool for sheet metal forming has been produced.

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Tateno, Toshitake, Akira Kakuta, Hayate Ogo e Takaya Kimoto. "Ultrasonic Vibration-Assisted Extrusion of Metal Powder Suspension for Additive Manufacturing". International Journal of Automation Technology 12, n. 5 (5 settembre 2018): 775–83. http://dx.doi.org/10.20965/ijat.2018.p0775.

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Additive manufacturing (AM) using metal materials can be used to manufacture metal parts with complex shapes that are difficult to manufacture with subtractive processing. Recently, numerous commercial AM machines for metallic materials have been developed. The primary types of AM using metallic materials are powder bed fusion or direct energy deposition. Other types using metallic materials have not been adequately studied. In this study, the use of the material extrusion (ME) type of AM is investigated. The aim is to use metallic materials not only for fabricating metal parts but also for adding various properties to base materials, e.g., electric conductivity, thermal conductivity, weight, strength, and color of plastics. ME is appropriate for use with various materials by mixing different types of filler. However, there is a problem in that the high density of metal fillers generates unstable extrusion. Therefore, ultrasonic vibration was used for assisting extrusion. A prototype system was developed using an extrusion nozzle vibrated by an ultrasonic homogenizer. The experimental results showed that the ultrasonic vibration allows materials to be extruded smoothly. Three dimensional (3D) shapes could be built by multi-layer deposition with a thixotropic polymer containing a highly concentrated steel powder. As one application, a 3D-shaped object was fabricated as a sintered object. After the vibration effect in the extrusion process of steel powder and clay was confirmed, a 3D object built by the proposed method was sintered through a baking process.

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Jabbari, Amin, e Karen Abrinia. "A metal additive manufacturing method: semi-solid metal extrusion and deposition". International Journal of Advanced Manufacturing Technology 94, n. 9-12 (25 settembre 2017): 3819–28. http://dx.doi.org/10.1007/s00170-017-1058-7.

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Langelandsvik, Geir, Mathieu Grandcolas, Kristian G. Skorpen, Trond Furu, Odd M. Akselsen e Hans Jørgen Roven. "Development of Al-TiC Wire Feedstock for Additive Manufacturing by Metal Screw Extrusion". Metals 10, n. 11 (6 novembre 2020): 1485. http://dx.doi.org/10.3390/met10111485.

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The development of customised aluminium alloys for welding and additive manufacturing (AM) is proposed to solve several quality issues and to enhance the mechanical integrity of components. The introduction of ceramic grain refining agents shows great potential as alloy addition as to limit cracking susceptibility and increase the strength. Thus, a versatile solid-state manufacturing route for nanoparticle reinforced aluminium wires has been developed based on the metal screw extrusion principle. In fact, the Al-Si alloy AA4043 mixed with 1 wt.% TiC nanoparticles has been manufactured as a wire. The accumulated strain on the material during metal screw extrusion has been estimated, classifying the process as a severe plastic deformation (SPD) method. A chemical reaction between silicon and TiC particles after metal screw extrusion was found, possibly limiting the grain refining effect. Electric arc bead-on-plate deposition was performed with metal screw extruded and commercial material. The addition of TiC induced a grain morphology transition from columnar to equiaxed after electric arc deposition, and increased the hardness. A high amount of porosity was found in the AA4043-TiC material, probably arising from hydrogen contamination on TiC surfaces prior to metal screw extrusion. The results are encouraging as a new direction for aluminium alloy development for additive manufacturing.

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Krinitcyn, Maksim, Alexandr Pervikov, Natalya Svarovskaya, Alexandr Lozhkomoev e Marat Lerner. "Extrusion-Based Additive Manufacturing of the Ti6Al4V Alloy Parts". Coatings 13, n. 6 (8 giugno 2023): 1067. http://dx.doi.org/10.3390/coatings13061067.

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The paper shows the possibility of synthesizing microparticles coated with nanoparticles by electric explosion of a wire made of Ti-6Al-4V alloy. Particles in which the core is a microparticle and the shell of a nanoparticle can provide effective sliding of the microparticles relative to each other and are promising for obtaining flowable metal-polymer compositions filled with powder up to 70 vol.%. Such compositions are promising feedstocks for the additive molding of complex metal parts, for example, customized implants from the Ti-6Al-4V alloy, by material extrusion. The article describes the properties of feedstock based on micro- and nanoparticles of the Ti-6Al-4V alloy, the microstructure and some mechanical properties of sintered samples. The structure, bending strength and Vickers hardness of additively formed samples sintered at a temperature of 1200 °C was investigated.

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Van Sice, Corrie, e Jeremy Faludi. "COMPARING ENVIRONMENTAL IMPACTS OF METAL ADDITIVE MANUFACTURING TO CONVENTIONAL MANUFACTURING". Proceedings of the Design Society 1 (27 luglio 2021): 671–80. http://dx.doi.org/10.1017/pds.2021.67.

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AbstractMetal additive manufacturing (AM) is revered for the design freedom it brings, but is it environmentally better or worse than conventional manufacturing? Since few direct comparisons are published, this study compared AM data from life-cycle assessment literature to conventional manufacturing data from the Granta EduPack database. The comparison included multiple printing technologies for steel, aluminum, and titanium. Results showed that metal AM had far higher CO2 footprints per kg of material processed than casting, extrusion, rolling, forging, and wire drawing, so it is usually a less sustainable choice than these. However, there were circumstances where it was a more sustainable choice, and there was significant overlap between these circumstances and aerospace industry use of metal AM. Notably, lightweight parts reducing embodied material impacts, and reducing use-phase impacts through fuel efficiency. Finally, one key finding was the irrelevance of comparing machining to AM per kg of material processed, since one is subtractive and the other is additive. Recommendations are given for future studies to use more relevant functional units to provide better comparisons.

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Annoni, Massimiliano, Hermes Giberti e Matteo Strano. "Feasibility Study of an Extrusion-based Direct Metal Additive Manufacturing Technique". Procedia Manufacturing 5 (2016): 916–27. http://dx.doi.org/10.1016/j.promfg.2016.08.079.

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Jiang, Dayue, e Fuda Ning. "Bi-metal structures fabricated by extrusion-based sintering-assisted additive manufacturing". Journal of Manufacturing Processes 98 (luglio 2023): 216–22. http://dx.doi.org/10.1016/j.jmapro.2023.05.025.

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Zhou, Longfei, Jenna Miller, Jeremiah Vezza, Maksim Mayster, Muhammad Raffay, Quentin Justice, Zainab Al Tamimi, Gavyn Hansotte, Lavanya Devi Sunkara e Jessica Bernat. "Additive Manufacturing: A Comprehensive Review". Sensors 24, n. 9 (23 aprile 2024): 2668. http://dx.doi.org/10.3390/s24092668.

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Additive manufacturing has revolutionized manufacturing across a spectrum of industries by enabling the production of complex geometries with unparalleled customization and reduced waste. Beginning as a rapid prototyping tool, additive manufacturing has matured into a comprehensive manufacturing solution, embracing a wide range of materials, such as polymers, metals, ceramics, and composites. This paper delves into the workflow of additive manufacturing, encompassing design, modeling, slicing, printing, and post-processing. Various additive manufacturing technologies are explored, including material extrusion, VAT polymerization, material jetting, binder jetting, selective laser sintering, selective laser melting, direct metal laser sintering, electron beam melting, multi-jet fusion, direct energy deposition, carbon fiber reinforced, laminated object manufacturing, and more, discussing their principles, advantages, disadvantages, material compatibilities, applications, and developing trends. Additionally, the future of additive manufacturing is projected, highlighting potential advancements in 3D bioprinting, 3D food printing, large-scale 3D printing, 4D printing, and AI-based additive manufacturing. This comprehensive survey aims to underscore the transformative impact of additive manufacturing on global manufacturing, emphasizing ongoing challenges and the promising horizon of innovations that could further elevate its role in the manufacturing revolution.

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Sartini, Mikhailo, Iacopo Bianchi, Alessio Vita, Michele Germani e Marco Mandolini. "An analytic cost model for bound metal deposition". Proceedings of the Design Society 4 (maggio 2024): 1819–28. http://dx.doi.org/10.1017/pds.2024.184.

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AbstractMetal material extrusion is a family of metal additive manufacturing that includes atomic diffusion additive manufacturing (ADAM) and bound metal deposition (BMD). In the literature, there are just a few cost models for ADAM and no one for BMD. The paper presents an analytic cost model for BMD. It considers the entire process: pre-processing, printing and post-processing. The total manufacturing cost is split into material, machine, labour, energy and consumables items. The cost model validation on a 3D-printed part determined an accuracy of 98%.

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Blindheim, Jørgen, Torgeir Welo e Martin Steinert. "Investigating the Mechanics of Hybrid Metal Extrusion and Bonding Additive Manufacturing by FEA". Metals 9, n. 8 (24 luglio 2019): 811. http://dx.doi.org/10.3390/met9080811.

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Hybrid Metal Extrusion & Bonding Additive Manufacturing (HYB-AM) is a hybrid manufacturing technology for the deposition of layered metal structures. This new deposition process is a complex metal forming operation, yet there is significant lack of knowledge regarding the governing mechanisms. In this work, we have used finite element analysis (FEA) to study material flow in the extruder, as well as the conditions at the interfaces of the deposited extrudate and the substrate, aiming to identify and characterize the process parameters involved. Analysis of the material flow shows that the extrusion pressure is virtually independent of the deposition rate. Furthermore, from the simulations of the material deposition sequence, it is clearly visible how the contact pressure at the interface will drop below the bonding threshold if the feed speed is too high relative to the material flow through the die. The reduced pressure also leads to the formation of a ‘gas-pocket’ inside the die, thus further degrading the conditions for bonding. The analyses of the process have provided valuable insights for the further development and industrialization of the process.

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Sakib-Uz-Zaman, Chowdhury, e Mohammad Abu Hasan Khondoker. "A Review on Extrusion Additive Manufacturing of Pure Copper". Metals 13, n. 5 (28 aprile 2023): 859. http://dx.doi.org/10.3390/met13050859.

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Copper, due to its high thermal and electrical conductivity, is used extensively in many industries such as electronics, aerospace, etc. In the literature, researchers have utilized different additive manufacturing (AM) techniques to fabricate parts with pure copper; however, each technique comes with unique pros and cons. Among others, material extrusion (MEX) is a noteworthy AM technique that offers huge potential to modify the system to be able to print copper parts without a size restriction. For that purpose, copper is mixed with a binder system, which is heated in a melt chamber and then extruded out of a nozzle to deposit the material on a bed. The printed part, known as the green part, then goes through the de-binding and sintering processes to remove all the binding materials and densify the metal parts, respectively. The properties of the final sintered part depend on the processing and post-processing parameters. In this work, nine published articles are identified that focus on the 3D printing of pure copper parts using the MEX AM technique. Depending on the type of feedstock and the feeding mechanism, the MEX AM techniques for pure copper can be broadly categorized into three types: pellet-fed screw-based printing, filament-fed printing, and direct-ink write-based printing. The basic principles of these printing methods, corresponding process parameters, and the required materials and feedstock are discussed in this paper. Later, the physical, electrical, and mechanical properties of the final parts printed from these methods are discussed. Finally, some prospects and challenges related to the shrinkage of the printed copper part during post-processing are also outlined.

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Zhang, Zhicheng, e Ismail Fidan. "Machine Learning-Based Void Percentage Analysis of Components Fabricated with the Low-Cost Metal Material Extrusion Process". Materials 15, n. 12 (17 giugno 2022): 4292. http://dx.doi.org/10.3390/ma15124292.

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Additive manufacturing (AM) is a widely used layer-by-layer manufacturing process. Material extrusion (ME) is one of the most popular AM techniques. Lately, low-cost metal material extrusion (LCMME) technology is developed to perform metal ME to produce metallic parts with the ME technology. This technique is used to fabricate metallic parts after sintering the metal infused additively manufactured parts. Both AM and sintering process parameters will affect the quality of the final parts. It is evident that the sintered parts do not have the same mechanical properties as the pure metal parts fabricated by the traditional manufacturing processes. In this research, several machine learning algorithms are used to predict the size of the internal voids of the final parts based on the collected data. Additionally, the results show that the neural network (NN) is more accurate than the support vector regression (SVR) on prediction.

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Ortega Varela de Seijas, Manuel, Andreas Bardenhagen, Thomas Rohr e Enrico Stoll. "Indirect Induction Sintering of Metal Parts Produced through Material Extrusion Additive Manufacturing". Materials 16, n. 2 (16 gennaio 2023): 885. http://dx.doi.org/10.3390/ma16020885.

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Avoiding loose powders and resins, material extrusion additive manufacturing is a powerful technique to produce near-net shape parts, being a cheap and safe alternative for developing complex industrial-grade products. Filaments embedded with a high packing density of metallic or ceramic granules are being increasingly used, resulting in almost fully dense parts, whereby geometries are shaped, debinded and sintered sequentially until the completion of the part. Traditionally, “brown” debinded geometries are transported to conventional furnaces to densify the powder compacts, requiring careful tailoring of the heating profiles and sintering environment. This approach is decoupled and often involves time-consuming post-processing, whereby after the completion of the shaping and debinding steps, the parts need to be transported to a sintering furnace. Here, it is shown that sintering via indirect induction heating of a highly filled commercially available filament embedded with stainless steel 316L powder can be an effective route to densify Fused Filament Fabricated (FFF) parts. The results show that densities of 99.8% can be reached with very short soaking times, representing a significant improvement compared to prior methods. A hybrid machine is proposed, whereby a custom-built machine is integrated with an induction heater to combine FFF with local indirect induction sintering. Sintering in situ, without the need for part transportation, simplifies the processing of metal parts produced through material extrusion additive manufacturing.

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Rosnitschek, Tobias, Johannes Glamsch, Christopher Lange, Bettina Alber-Laukant e Frank Rieg. "An Automated Open-Source Approach for Debinding Simulation in Metal Extrusion Additive Manufacturing". Designs 5, n. 1 (2 gennaio 2021): 2. http://dx.doi.org/10.3390/designs5010002.

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As an alternative to powder-bed based processes, metal parts can be additively manufactured by extrusion based additive manufacturing. In this process, a highly filled polymer filament is deposited and subsequently debindered and sintered. Choosing a proper orientation of the part that satisfies the requirements of the debinding and sintering processes is crucial for a successful manufacturing process. To determine the optimal orientation for debinding, first, the part must be scaled in order to compensate the sinter induced shrinkage. Then, a finite element analysis is performed to verify that the maximum stresses due to the dead load do not exceed the critical stress limits. To ease this selection process, an approach based on open source software is shown in this article to efficiently determine a part’s optimal orientation during debinding. This automates scaling, debinding simulation, and postprocessing for all six main directions. The presented automated simulation framework is examined on three application examples and provides plausible results in a technical context for all example parts, leading to more robust part designs and a reduction of experimental trial and error. Therefore, the presented framework is a useful tool in the product development process for metal extrusion additive manufacturing applications.

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Mohammadizadeh, Mahdi, Hao Lu, Ismail Fidan, Khalid Tantawi, Ankit Gupta, Seymur Hasanov, Zhicheng Zhang, Frank Alifui-Segbaya e Allan Rennie. "Mechanical and Thermal Analyses of Metal-PLA Components Fabricated by Metal Material Extrusion". Inventions 5, n. 3 (24 agosto 2020): 44. http://dx.doi.org/10.3390/inventions5030044.

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Metal additive manufacturing (AM) has gained much attention in recent years due to its advantages including geometric freedom and design complexity, appropriate for a wide range of potential industrial applications. However, conventional metal AM methods have high-cost barriers due to the initial cost of the capital equipment, support, and maintenance, etc. This study presents a low-cost metal material extrusion technology as a prospective alternative to the production of metallic parts in additive manufacturing. The filaments used consist of copper, bronze, stainless steel, high carbon iron, and aluminum powders in a polylactic acid matrix. Using the proposed fabrication technology, test specimens were built by extruding metal/polymer composite filaments, which were then sintered in an open-air furnace to produce solid metallic parts. In this research, the mechanical and thermal properties of the built parts are examined using tensile tests, thermogravimetric, thermomechanical and microstructural analysis.

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Sæterbø, Mathias, e Wei Deng Solvang. "Evaluating the cost competitiveness of metal additive manufacturing – A case study with metal material extrusion". CIRP Journal of Manufacturing Science and Technology 45 (ottobre 2023): 113–24. http://dx.doi.org/10.1016/j.cirpj.2023.06.005.

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Jimbo, Koki, e Toshitake Tateno. "Shape Contraction in Sintering of 3D Objects Fabricated via Metal Material Extrusion in Additive Manufacturing". International Journal of Automation Technology 13, n. 3 (5 maggio 2019): 354–60. http://dx.doi.org/10.20965/ijat.2019.p0354.

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Additive manufacturing (AM) using metal materials (metal AM) is useful in the fabrication of metal parts with complex shapes, which are difficult to manufacture via subtractive processing. Metal AM is employed in the manufacture of final products as well as in prototyping. Recently, certain metal-AM machines have been commercialized. Powder-bed fusion and direct energy deposition are the main types of metal AM; they require the use of a high-power laser or electron beam and most of them are highly expensive. On the other hand, AM machines of the material-extrusion (ME) type can fabricate metal parts at a low cost. ME is the method of extruding materials from a nozzle and fabricating thin layers. By mixing a metal filler with a base material, it is possible to impart various mechanical properties to the extruded material, such as electrical or thermal conductivity. If the extruded material is baked in a furnace after fabrication, the object can be sintered. During the sintering process, the fabricated objects always shrink and dimensional errors occur. One of the reasons for the shrinkage is that voids are generated inside the object after the degreasing process and collapse during the sintering process. Because the void is generated as a space by replacing a binder that becomes vaporized during the degreasing process, the shrinkage may be controlled by decreasing the content in polymers. In this study, the effect of the metal filler density on the shrinkage in shape was investigated through experiments using two types of metal ME AM. One type is the fused filament fabrication (FFF), in which a material that consists of a metal filler and fused plastics is extruded; the other type is the ultrasonic vibration-assisted ME (UVAME) device, in which a metal powder suspension with a small amount of thickening polymer is extruded. In the latter method, materials with an extremely high density in metal fillers were used; it was considered that degreasing was not required. Two types of specimens were fabricated using AM devices; they were then degreased and sintered. The resulting shapes of the objects were measured with a 3D scanner and were compared. The experimental results showed that the shrinkage of the material with a high density of metal fillers was less than that of the material with a low density of metal fillers.

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Kedziora, Slawomir, Thierry Decker, Elvin Museyibov, Julian Morbach, Steven Hohmann, Adrian Huwer e Michael Wahl. "Strength Properties of 316L and 17-4 PH Stainless Steel Produced with Additive Manufacturing". Materials 15, n. 18 (9 settembre 2022): 6278. http://dx.doi.org/10.3390/ma15186278.

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The number of additive manufacturing methods and materials is growing rapidly, leaving gaps in the knowledge of specific material properties. A relatively recent addition is the metal-filled filament to be printed similarly to the fused filament fabrication (FFF) technology used for plastic materials, but with additional debinding and sintering steps. While tensile, bending, and shear properties of metals manufactured this way have been studied thoroughly, their fatigue properties remain unexplored. Thus, the paper aims to determine the tensile, fatigue, and impact strengths of Markforged 17-4 PH and BASF Ultrafuse 316L stainless steel to answer whether the metal FFF can be used for structural parts safely with the current state of technology. They are compared to two 316L variants manufactured via selective laser melting (SLM) and literature results. For extrusion-based additive manufacturing methods, a significant decrease in tensile and fatigue strength is observed compared to specimens manufactured via SLM. Defects created during the extrusion and by the pathing scheme, causing a rough surface and internal voids to act as local stress risers, handle the strength decrease. The findings cast doubt on whether the metal FFF technique can be safely used for structural components; therefore, further developments are needed to reduce internal material defects.

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Dârlău, Lucian-Corneliu. "Obtaining Metal Parts by Additive Manufacturing, as an Alternative to Traditional Manufacturing Methods – A Review". Bulletin of the Polytechnic Institute of Iași. Machine constructions Section 69, n. 1 (1 marzo 2023): 61–80. http://dx.doi.org/10.2478/bipcm-2023-0005.

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Abstract The advantages of Additive Manufacturing (AM) over conventional manufacturing processes are incontestable: complex geometries of obtained parts, wide variety of materials (polymers, composites, low melting metal alloys) used, simple and cost-effective process. Material Extrusion (ME) (piston, filament or screw) is the most widespread AM technology. In this paper, a comparative analysis of different materials used in high reinforcement 3D printing is made. Thus, ceramic and metallic composites, composites with titanium particles, AISI M2 high speed steel powder and Nickel 625 alloy are presented. The conclusion of each study is that increasing powder concentration (up to 65%, by volume) increases parts density (up to 90%), improves sintering process, but narrows process parameters. A balance between raw material properties and processing parameters must be sought to obtain custom parts with optimal properties.

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POLISHCHUK, Oleg, Andrii POLISHCHUK, Svitlana LISEVICH, Anatoliy ZALIZETSKYI e Vasiliy MELNYK. "THE MANUFACTURING PRODUCTS AND PARTS BY 3D-PRINTING METHOD FROM COMPOSITE FILAMENTS WITH HIGH METAL CONTENT". Herald of Khmelnytskyi National University. Technical sciences 309, n. 3 (26 maggio 2022): 104–10. http://dx.doi.org/10.31891/2307-5732-2022-309-3-104-110.

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It is established that one of the most promising areas of development of modern engineering is the development of new technologies for rapid production (rapid manufacturing), the essence of which is the layered design of powder products based on CAD model, ie model whose three-dimensional geometry is described digitally by using solid modeling programs (AutoCAD, SolidWorks, Compas-3D, CATIA, ProE, etc.). The main advantages of using additive technologies, including 3D printing with filaments containing metals. The types of 3D printers that print metal are considered. The use of metal powders in 3D printing technologies is described. The main characteristics and properties of such metals, TI titanium, stainless steel SS, aluminum Al, copper Cu, FE iron and alloys based on them can be used as materials or additives in additive technologies. The advantages of their use over traditional technologies (casting, rolling, etc.) are described. The scheme of technological process of manufacturing products of industry mechanical engineering by a 3D printing with a high metal content is given. Each of the stages of the technological process is considered and described. Stainless steel metal powder was selected for the manufacture of filament and its chemical composition is investigated. Experimental studies have been conducted to determine the mechanical, thermophysical and rheological characteristics of polymeric materials used for the manufacture of 3D prints. On the basis of the studies, it is proposed to use Plastic powder as a connecting element in the filament. The design of the auger for supplying the material of the extrusion machine is designed and manufactured. The form of the extrusion head is developed and selected, which sets the diameter of the filament being made. A 3D printer for printing products and parts with a high metal content was selected and improved. Experimental studies of the wear of the 3D printer’s extruder nozzle on contact with the abrasive thread.

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Liu, Lanbing, Chao Ding, Yunhui Mei e Guoquan Lu. "Tailoring a Silver Paste for Additive Manufacturing of Co-Fired Ferrite Magnetic Components". Materials 12, n. 5 (11 marzo 2019): 817. http://dx.doi.org/10.3390/ma12050817.

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Additive manufacturing (AM), or 3D-printing, has the potential for rapid prototyping of innovative designs of magnetic components used in power electronics converters. In this study, we tailored a silver paste as the metal feedstock of an extrusion 3D printer so that the metal would be compatible with a ferrite paste feedstock for 3D-printing of ferrite magnetic components. We focused on adjusting the metal formulation to match its shrinkage to that of the ferrite and to improve adhesion during the co-sintering process of the printed part. We found that a 5 wt % addition of ferrite powder in the metal paste can achieve matched shrinkage and strong adhesion. Evaluation of the co-sintered magnetic components showed no significant defects, such as cracks, warpage, or delamination, between the metal and ferrite. The shear strength between the two sintered materials was greater than 50 MPa, and the electrical resistivity of the sintered metal winding was less than twice that of the bulk silver, which is lower than those of most 3D-printed winding metals reported in the literature.

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Sharma, Gourav K., Piyush Pant, Prashant K. Jain, Pavan K. Kankar e Puneet Tandon. "On the suitability of induction heating system for metal additive manufacturing". Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 235, n. 1-2 (14 luglio 2020): 219–29. http://dx.doi.org/10.1177/0954405420937854.

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Induction heating is a non-contact-based energy source that has the potential to quickly melt the metal and become the alternate energy source that can be used for additive manufacturing. At present, induction heating is widely used in various industrial applications such as melting, preheating, heat treatment, welding, and brazing. The potential of this source has not been explored in the additive manufacturing domain. However, the use of induction heating in additive manufacturing could lead to low-cost part fabrication as compared to other energy sources such as laser or electron beam. Therefore, this study explores the feasibility of this energy source in additive manufacturing for fabricating parts of metallic materials. An experimental system has been developed by modifying an existing delta three-dimensional printer. An induction heater coil has been incorporated to extruder head for semi-solid processing of the metal alloy. In order to test the viability of the developed system, aluminium material in the filament form has been processed. Obtained results have shown that the induction heating–based energy source is capable of processing metallic materials having a melting point up to 1000° C. The continuous extrusion of the material has been achieved by controlling the extruder temperature using a proportional integral derivative–based controller and k-type thermocouple. The study also discusses various issues and challenges that occurred during the melting of metal with induction heating. The outcomes of this study may be a breakthrough in the area of metal-based additive manufacturing.

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Suwanpreecha, Chanun, e Anchalee Manonukul. "A Review on Material Extrusion Additive Manufacturing of Metal and How It Compares with Metal Injection Moulding". Metals 12, n. 3 (28 febbraio 2022): 429. http://dx.doi.org/10.3390/met12030429.

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Material extrusion additive manufacturing of metal (metal MEX), which is one of the 3D printing processes, has gained more interests because of its simplicity and economics. Metal MEX process is similar to the conventional metal injection moulding (MIM) process, consisting of feedstock preparation of metal powder and polymer binders, layer-by-layer 3D printing (metal MEX) or injection (MIM) to create green parts, debinding to remove the binders and sintering to create the consolidated metallic parts. Due to the recent rapid development of metal MEX, it is important to review current research work on this topic to further understand the critical process parameters and the related physical and mechanical properties of metal MEX parts relevant to further studies and real applications. In this review, the available literature is systematically summarised and concluded in terms of feedstock, printing, debinding and sintering. The processing-related physical and mechanical properties, i.e., solid loading vs. dimensional shrinkage maps, sintering temperature vs. relative sintered density maps, stress vs. elongation maps for the three main alloys (316L stainless steel, 17-4PH stainless steel and Ti-6Al-4V), are also discussed and compared with well-established MIM properties and MIM international standards to assess the current stage of metal MEX development.

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Lotfi, Zahraa, Amir Mostafapur e Ahmad Barari. "Properties of Metal Extrusion Additive Manufacturing and Its Application in Digital Supply Chain Management". IFAC-PapersOnLine 54, n. 1 (2021): 199–204. http://dx.doi.org/10.1016/j.ifacol.2021.08.024.

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Hertle, Sebastian, Tobias Kleffel, Andreas Wörz e Dietmar Drummer. "Production of polymer-metal hybrids using extrusion-based additive manufacturing and electrochemically treated aluminum". Additive Manufacturing 33 (maggio 2020): 101135. http://dx.doi.org/10.1016/j.addma.2020.101135.

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You, Siyao, Dayue Jiang, Fuji Wang e Fuda Ning. "Anisotropic sintering shrinkage behavior of stainless steel fabricated by extrusion-based metal additive manufacturing". Journal of Manufacturing Processes 101 (settembre 2023): 1508–20. http://dx.doi.org/10.1016/j.jmapro.2023.07.026.

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Di Pompeo, Valerio, Eleonora Santecchia, Alberto Santoni, Kamal Sleem, Marcello Cabibbo e Stefano Spigarelli. "Microstructure and Defect Analysis of 17-4PH Stainless Steel Fabricated by the Bound Metal Deposition Additive Manufacturing Technology". Crystals 13, n. 9 (28 agosto 2023): 1312. http://dx.doi.org/10.3390/cryst13091312.

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Abstract (sommario):

Metal additive manufacturing (AM) technologies can be classified according to the physical process involving the raw material as fusion-based and solid-state processes. The latter includes sintering-based technologies, which are aligned with conventional fabrication techniques, such as metal injection molding (MIM), and take advantage of the freeform fabrication of the initial green part. In the present work, 17-4PH stainless steel samples were fabricated by material extrusion, or rather bound metal deposition (BMD), a solid-state AM technology. The powder-based raw material was characterized together with samples fabricated using different angular infill strategies. By coupling different characterization technologies, it was possible to identify and classify major properties and defects of the raw material and the fabricated samples. In addition, microstructural modifications were found to be linked with the mesostructural defects typical of the BMD solid-state additive manufacturing technology applied to metals.

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Siedlecki, Krzysztof, Marcin Słoma e Andrzej Skalski. "Comparison between Micro-Powder Injection Molding and Material Extrusion Additive Manufacturing of Metal Powders for the Fabrication of Sintered Components". Materials 16, n. 23 (22 novembre 2023): 7268. http://dx.doi.org/10.3390/ma16237268.

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Original compositions based on iron micro-powders and an organic binder mixture were developed for the fabrication of sintered metallic elements with micro-powder injection molding (µPIM) and material extrusion additive manufacturing of metal powders (MEX). The binder formulation was thoroughly adjusted to exhibit rheological and thermal properties suitable for µPIM and MEX. The focus was set on adapting the proper binder composition to meet the requirements for injection/extrusion and, at the same time, to have comparable thermogravimetric characteristics for the thermal debinding and sintering process. A basic analysis of the forming process indicates that the pressure has a low influence on clogging, while the temperature of the material and mold/nozzle impacts the viscosity of the composition significantly. The influence of the Fe micro-powder content in the range of 45–60 vol.% was evaluated against the injection/extrusion process parameters and properties of sintered elements. Different debinding and sintering processes (chemical and thermal) were evaluated for the optimal properties of the final samples. The obtained sintered elements were of high quality and showed minor signs of binder-related flaws, with shrinkage in the range of 10–15% for both the injection-molded and 3D printed parts. These results suggest that, with minor modifications, compositions tailored for the PIM technique can be adapted for the additive manufacturing of metal parts, achieving comparable characteristics of the parts obtained for both forming methods.

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Sadaf, Mahrukh, Mario Bragaglia, Lidija Slemenik Perše e Francesca Nanni. "Advancements in Metal Additive Manufacturing: A Comprehensive Review of Material Extrusion with Highly Filled Polymers". Journal of Manufacturing and Materials Processing 8, n. 1 (16 gennaio 2024): 14. http://dx.doi.org/10.3390/jmmp8010014.

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Abstract (sommario):

Additive manufacturing (AM) has attracted huge attention for manufacturing metals, ceramics, highly filled composites, or virgin polymers. Of all the AM methods, material extrusion (MEX) stands out as one of the most widely employed AM methods on a global scale, specifically when dealing with thermoplastic polymers and composites, as this technique requires a very low initial investment and usage simplicity. This review extensively addresses the latest advancements in the field of MEX of feedstock made of polymers highly filled with metal particles. After developing a 3D model, the polymeric binder is removed from the 3D-printed component in a process called debinding. Furthermore, sintering is conducted at a temperature below the melting temperature of the metallic powder to obtain the fully densified solid component. The stages of MEX-based processing, which comprise the choice of powder, development of binder system, compounding, 3D printing, and post-treatment, i.e., debinding and sintering, are discussed. It is shown that both 3D printing and post-processing parameters are interconnected and interdependent factors, concurring in determining the resulting mechanical properties of the sintered metal. In particular, the polymeric binder, along with its removal, results to be one of the most critical factors in the success of the entire process. The mechanical properties of sintered components produced through MEX are generally inferior, compared with traditional techniques, as final MEX products are more porous.

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Li, Zhong, Xiao Gang Hu, Hong Xing Lu e Qiang Zhu. "Microstructure Design of Semi-Solid Slurry for Metal Direct Writing". Solid State Phenomena 348 (28 agosto 2023): 33–38. http://dx.doi.org/10.4028/p-qdk1x5.

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Metal direct writing in semi-solid slurry is an innovative technology to realize low-cost printing of load-bearing parts in contrast to laser-based additive manufacturing. However, it is challenging to achieve near net-forming of 3D parts in the current stage because of the out of controlled microstructure and hence the unstable macro extrusion of the used semi-solid slurry. Here, mixed powder remelting (MPR) is introduced to actively design the characteristics of solid phases, i.e., solid fraction, shape factor, and size distribution. Specifically, high-melting-point pure Al powder served as the dispersed solid phases in the liquid phase that transformed from Al-Si alloy powder after remelting, leading to hypoeutectic Al-Si semi-solid slurry. The effectiveness of this approach was experimentally examined and kinetically modelled, to prepare semi-solid slurry with pre-set microstructure. The improved extrusion stability of semi-solid slurry can be anticipated, and it is universal for manufacturing of metal matrix composites slurry.

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Mahr, Alexander, Thomas Schütt, Tobias Rosnitschek, Stephan Tremmel e Frank Döpper. "Evaluation of Powder- and Extrusion-Based Metal Additive Manufacturing Processes for the Sustainable Fabrication of Spare Parts in Electromobility". Sustainability 16, n. 8 (19 aprile 2024): 3425. http://dx.doi.org/10.3390/su16083425.

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Electromobility promises to efficiently mitigate consequences of increasing traffic volume and its accompanied greenhouse gas emissions. On an individual level, electrified bikes allow emission free electrified mobility at moderate costs, and consequently their stock has increased significantly in recent years. This simultaneously increases the demand for spare parts, which are often manufacturer- or application-specific, and due to many variants, challenging to provide for the market. This article evaluates powder-based and extrusion-based metal additive manufacturing of a typical electrified bike component. The overarching objective is to establish a sustainable spare parts supply in the field of electromobility by manufacturing spare parts in a resource-efficient and decentralized manner. This approach aims to eliminate the need for physical storage space and long transport routes for the provision of spare parts, while significantly increasing the service life of e-bikes. The investigation demonstrates how these parts can be additively manufactured function equivalent and with sufficient mechanical properties, also taking economical aspects into account. Furthermore, the needed resources and related environmental consequences for metal-based additive manufacturing spare-part production are compared for both process routes. The results show that both routes are capable of producing spare-parts at comparatively the same mechanical performance, with the mechanical performance of the initial part clearly surpassed. Furthermore, it can be observed that both routes exhibit comparable resource costs, with the powder bed fusion of metals using laser beams showing significantly lower energy and gas costs by more than ten times, but higher material costs that are approximately twice as high as those of atomic diffusion additive manufacturing. Therefore, additive manufacturing offers a promising opportunity to rapidly produce parts in small quantities which are resource efficient.

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Sharma, Gourav K., Piyush Pant, Prashant K. Jain, Pavan K. Kankar e Puneet Tandon. "Analysis of novel induction heating extruder for additive manufacturing using aluminum filament". Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 235, n. 12 (8 maggio 2021): 1961–70. http://dx.doi.org/10.1177/09544054211014451.

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Induction Heating (IH) method is gaining traction in the field of Additive Manufacturing (AM) as it is a low cost, clean, safe, and precise energy source. Wire as a feedstock material is highly efficient as compared to the powder form in terms of material utilization and economic viability. Thus, the combination of IH and wire feedstock delivery to additive manufacture a part has been explored on an in-house developed novel AM setup. The processing of aluminum wire (Al-5356) in semi-solid form from the extruder, heated using IH method has been performed. The approach adopted in this paper is to perform an in situ infrared imaging to analyze the evolution of thermal field during the extruder heating and metal deposition process. An effective thermal cartography has been undertaken to acquire temperature history of filament, extruder, and deposition process. The temperature profile plot is utilized to understand the temperature distribution and average temperature in the heating, extrusion, and layering process during layer fabrication. The presented work facilitates a priori anticipation to utilize IH as a potential energy source for the metal AM systems.

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Chang, Gaoyuan, Xiaoxun Zhang, Fang Ma, Cheng Zhang e Luyang Xu. "Printing, Debinding and Sintering of 15-5PH Stainless Steel Components by Fused Deposition Modeling Additive Manufacturing". Materials 16, n. 19 (23 settembre 2023): 6372. http://dx.doi.org/10.3390/ma16196372.

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Metal FDM technology overcomes the problems of high cost, high energy consumption and high material requirements of traditional metal additive manufacturing by combining FDM and powder metallurgy and realizes the low-cost manufacturing of complex metal parts. In this work, 15-5PH stainless steel granules with a powder content of 90% and suitable for metal FDM were developed. The flowability and formability of the feedstock were investigated and the parts were printed. A two-step (solvent and thermal) debinding process is used to remove the binder from the green part. After being kept at 75 °C in cyclohexane for 24 h, the solvent debinding rate reached 98.7%. Following thermal debinding, the material’s weight decreased by slightly more than 10%. Sintering was conducted at 1300 °C, 1375 °C and 1390 °C in a hydrogen atmosphere. The results show that the shrinkage of the sintered components in the X-Y-Z direction remains quite consistent, with values ranging from 13.26% to 19.58% between 1300 °C and 1390 °C. After sintering at 1390 °C, the material exhibited a relative density of 95.83%, a hardness of 101.63 HRBW and a remarkable tensile strength of 770 MPa. This work realizes the production of metal parts using 15-5PH granules’ extrusion additive manufacturing, providing a method for the low-cost preparation of metal parts. And it provides a useful reference for the debinding and sintering process settings of metal FDM. In addition, it also enriches the selection range of materials for metal FDM.

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Galati, Manuela, e Paolo Minetola. "Analysis of Density, Roughness, and Accuracy of the Atomic Diffusion Additive Manufacturing (ADAM) Process for Metal Parts". Materials 12, n. 24 (9 dicembre 2019): 4122. http://dx.doi.org/10.3390/ma12244122.

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Atomic Diffusion Additive Manufacturing (ADAM) is a recent layer-wise process patented by Markforged for metals based on material extrusion. ADAM can be classified as an indirect additive manufacturing process in which a filament of metal powder encased in a plastic binder is used. After the fabrication of a green part, the plastic binder is removed by the post-treatments of washing and sintering (frittage). The aim of this work is to provide a preliminary characterisation of the ADAM process using Markforged Metal X, the unique system currently available on the market. Particularly, the density of printed 17-4 PH material is investigated, varying the layer thickness and the sample size. The dimensional accuracy of the ADAM process is evaluated using the ISO IT grades of a reference artefact. Due to the deposition strategy, the final density of the material results in being strongly dependent on the layer thickness and the size of the sample. The density of the material is low if compared to the material processed by powder bed AM processes. The superficial roughness is strongly dependent upon the layer thickness, but higher than that of other metal additive manufacturing processes because of the use of raw material in the filament form. The accuracy of the process achieves the IT13 grade that is comparable to that of traditional processes for the production of semi-finished metal parts.

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Alexander, David, Bianca Myraih Ceballos, David Yapell, Christian Ruiz, Rod L. Borup e Tommy Rockward. "Suitability of Composite Feed-Stock Material for Bi-Polar Plates Using Low-Cost Additive Manufacturing". ECS Meeting Abstracts MA2022-02, n. 40 (9 ottobre 2022): 1456. http://dx.doi.org/10.1149/ma2022-02401456mtgabs.

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Extrusion-based 3D printing processes have the lowest cost for equipment and materials used in additive manufacturing (AM). Recently, the AM technology has been extended beyond the typical polymer-based parts to include the capability of printing metal parts via Bound Metal Deposition (BMD). This technological advancement has, in turn, increased the potential application range of printed components particularly for Polymer Electrolyte Fuel Cells (PEFC). Although AM offers some design and cost advantages over traditional manufacturing, the finished part, post processing, must yield acceptable bi-polar plate properties outlined by the Hydrogen and Fuel Cell Technologies Office (HFTO). The post-processing techniques employed are de-binding, sintering, and surface treatment which are performed in a single step process. Here we focus on corrosion resistance, electrical conductivity, area specific resistance and porosity as the key parameters to qualify the candidate bi-polar plate material. The objective of this study is to investigate the effects of thermal processing parameters on the commercial metal composite filament via various characterization methods such as linear sweep voltammetry, area specific resistance, and x-ray computed tomography.

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Galantucci, Luigi Maria, Alessandro Pellegrini, Maria Grazia Guerra e Fulvio Lavecchia. "3D Printing of parts using metal extrusion: an overview of shaping debinding and sintering technology". Advanced Technologies & Materials 47, n. 1 (15 giugno 2022): 25–32. http://dx.doi.org/10.24867/atm-2022-1-005.

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Additive Manufacturing (AM) is the fabrication of real three-dimensional objects from plastics and metals by adding material, layer by layer. One of the most common AM processes is the Material Extrusion (ME) based on different approaches: plunger, filament and screw. Material Extrusion technologies of metal-polymer composites is expanding and it mainly uses the filament or plunger-based approaches. The feedstock used is a mixture of metal powder (from 55 vol% to about 80 vol%) dispersed in a thermoplastic matrix, as the Metal Injection Molding (MIM) materials. The process consists of three steps: shaping, debinding and sintering. The first step provides the extrusion of filament to realize a primary piece called “green part”; subsequent steps, debinding and sintering, allow to obtain a full metal part by dissolving the polymeric binder. The latter can be carried out using solvents, heat and the combination of them. The interest toward this technology is driven by the possibility to replace other Metal AM technologies, such as Selective Laser Melting or Direct Energy Deposition, in sectors like rapid-tooling or mass production, with several benefits: simplicity, safety to use and saving material and energy. The aim of this keynote is to provide a general overview of the main metal ME technologies considering the more technical aspects such as process methodologies, 3D printing strategy, process parameters, materials and possible applications for the manufacturing of samples on a 3D consumer printer.

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Gong, Haijun, Cameron Crater, Ana Ordonez, Craig Ward, Madison Waller e Charles Ginn. "Material Properties and Shrinkage of 3D Printing Parts using Ultrafuse Stainless Steel 316LX Filament". MATEC Web of Conferences 249 (2018): 01001. http://dx.doi.org/10.1051/matecconf/201824901001.

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As a novel manufacturing methodology, 3D printing or additive manufacturing (AM) attracts much more attentions for complex structure fabrication, especially for manufacturing metal parts. A number of metal AM processes have been studied and commercialized. However, most of them are costly and less accessible. This paper introduces a material extrusion based 3D printing process for making austenitic stainless steel 316L part using a metal-polymer composite filament (Ultrafuse 316LX). The stainless steel 316L metal specimens are printed by a commonly used 3D printer loaded with Ultrafuse filament, followed by an industry standard debinding and sintering process. Tests are performed to understand the material properties, such as hardness, tensile strength, and microstructural characteristics, of the stainless steel 316L material. In addition, an artifact model is designed to estimate the part shrinkage after the debinding and sintering process. It is found that the stainless steel 316L part exhibits apparent shrinkage after sintering. But using the Ultrafuse filament for 3D printing could be an alternative way of making metal AM parts.

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Mata, Margarida, Mateus Pinto e José Costa. "Topological Optimization of a Metal Extruded Doorhandle using nTopology". U.Porto Journal of Engineering 9, n. 1 (23 gennaio 2023): 42–54. http://dx.doi.org/10.24840/2183-6493_009-001_001620.

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Entranceways are blocked with the use of doors. For these to be opened, door handles must be manipulated, making them one of the most used inventions in our lives. This article reviews the topological optimization of a door-handle design, its adaptation to being produced using Additive Manufacturing (AM), and the feasibility of Metal Extrusion as a part fabrication method. Two different door-handle designs were created and optimized with the introduction of lattices and generative design using nTopology software and later produced with Inconel 625 filament.

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Cañadilla, Antonio, Ana Romero, Gloria P. Rodríguez, Miguel Á. Caminero e Óscar J. Dura. "Mechanical, Electrical, and Thermal Characterization of Pure Copper Parts Manufactured via Material Extrusion Additive Manufacturing". Materials 15, n. 13 (1 luglio 2022): 4644. http://dx.doi.org/10.3390/ma15134644.

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Abstract (sommario):

Material Extrusion Additive Manufacturing (MEAM) is a novel technology to produce polymeric, metallic, and ceramic complex components. Filaments composed of a high-volume content of metal powder and a suitable binder system are needed to obtain metallic parts. Thermal and energetic controversies do not affect MEAM technology, although common in other additive manufacturing (AM) techniques. High thermal conductivity and reflectivity of copper to high-energy beams are the most challenging properties. A material extrusion technique to produce high density and quality copper parts is deeply studied in this research. Characterization of the filament, printed parts, brown parts and final sintered parts is provided. The sintering stage is evaluated through density analysis of the sintered copper parts, as well as their dimensional accuracy after part shrinkage inherent to the sintering process. The mechanical behavior of sintered parts is assessed through tensile, hardness and impact toughness tests. In addition, the measured electrical and thermal conductivities are compared to those obtained by other AM technologies. High-density components, with 95% of relative density, were successfully manufactured using MEAM technology. Similar or even superior mechanical, thermal and electrical properties than those achieved by other 3D printing processes such as Electron Beam Melting, Selective Laser Melting and Binder Jetting were obtained.

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Ecker, J. V., K. Dobrezberger, J. Gonzalez-Gutierrez, M. Spoerk, Ch Gierl-Mayer e H. Danninger. "Additive Manufacturing of Steel and Copper Using Fused Layer Modelling: Material and Process Development". Powder Metallurgy Progress 19, n. 2 (1 dicembre 2019): 63–81. http://dx.doi.org/10.1515/pmp-2019-0007.

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AbstractFused Layer Modelling (FLM) is one out of several material extrusion (ME) additive manufacturing (AM) methods. FLM usually deals with processing of polymeric materials but can also be used to process metal-filled polymeric systems to produce metallic parts. Using FLM for this purpose helps to save costs since the FLM hardware is cheap compared to e.g. direct metal laser processing hardware, and FLM offers an alternative route to the production of metallic components.To produce metallic parts by FLM, the methodology is different from direct metal processing technologies, and several processing steps are required: First, filaments consisting of a special polymer-metal composition are produced. The filament is then transformed into shaped parts by using FLM process technology. Subsequently the polymeric binder is removed (”debinding”) and finally the metallic powder body is sintered. Depending on the metal powder used, the binder composition, the FLM production parameters and also the debinding and sintering processes must be carefully adapted and optimized.The focal points of this study are as following:1. To confirm that metallic parts can be produced by using FLM plus debinding and sintering as an alternative route to direct metal additive manufacturing.2. Determination of process parameters, depending on the used metal powders (steel and copper) and optimization of each process step.3. Comparison of the production paths for the different metal powders and their debinding and sintering behavior as well as the final properties of the produced parts.The results showed that both materials were printable after adjusting the FLM parameters, metallic parts being produced for both metal powder systems. The production method and the sintering process worked out well for both powders. However there are specific challenges in the sintering process that have to be overcome to produce high quality metal parts. This study serves as a fundamental basis for understanding when it comes to the processing of steel and copper powder into metallic parts using FLM processing technology.

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Khan, Mohd Yunus, P. S. Rao e B. S. Pabla. "On the use of Copper Tool developed by Atomic Diffusion Additive Manufacturing (ADAM) Process for Electrical Discharge Machining". E3S Web of Conferences 455 (2023): 02014. http://dx.doi.org/10.1051/e3sconf/202345502014.

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This paper highlights the review of work done in the area of 3D printed tools for the spark machining process. In recent times, additive manufacturing has gained wide popularity in different sectors. The additive manufacturing process or 3D printing, is a method for creating three-dimensional objects by layering material. Using the additive manufacturing technique of atomic diffusion, a tool for electrical discharge machining was developed. In this method, a mixture of metal and polymer that are formed into wire was employed and kept in a cartridge. The material mix is deposited in similar to extrusion process. A computer software does all the calculation, costing, weight analysis and printing time assessment. The procedure of the same is discussed. The scanning electron microscopic analysis of the same is done along with porosity measurement using ImageJ software. The surface characteristics of the printed tool was measured with Gwyddion software. Discussion on applicability of printed tool for electrical discharge machining process is done. words.

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Blindheim, Jørgen, Torgeir Welo e Martin Steinert. "First demonstration of a new additive manufacturing process based on metal extrusion and solid-state bonding". International Journal of Advanced Manufacturing Technology 105, n. 5-6 (1 novembre 2019): 2523–30. http://dx.doi.org/10.1007/s00170-019-04385-8.

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Abstract In this paper, a new additive manufacturing (AM) process based on extrusion and solid-state bonding is presented. The process uses metal feedstock wire which is processed in a continuous rotary extruder in order to disperse the surface oxides of the feedstock and to provide the required bonding pressure. Simultaneously, the die outlet is scraping the contact surface to provide an oxide-free interface between the extrudate and the substrate. Optical analyses of samples from a layered structure produced from AA6082 reveal that the stringers are fully merged; however, some voids and cracks are observed between the individual stringers. Still, this initial demonstration indicates that the process, upon further development, has high potential of producing near-net-shape parts at high deposition rates.

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Suzuki, Tomoya, e Toshitake Tateno. "Effect of Material Temperature on Fabrication Accuracy of Metal Powder Extrusion Additive Manufacturing with Ultrasonic Vibration". Proceedings of Manufacturing Systems Division Conference 2022 (2022): 505. http://dx.doi.org/10.1299/jsmemsd.2022.505.

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Kain, M., M. Calaon, D. B. Pedersen e G. Tosello. "On the implementation of metal additive manufacturing in the tooling process chain for polymer profile extrusion". Procedia CIRP 93 (2020): 26–31. http://dx.doi.org/10.1016/j.procir.2020.03.141.

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Yi, Zhonghuai, Ting Shen, Huiwen Xiong, Xiao Kang, Lei Zhang e Kechao Zhou. "Strong and densified 3D metal-ceramic composite with strengthened layer structure by material extrusion additive manufacturing". Additive Manufacturing 84 (marzo 2024): 104136. http://dx.doi.org/10.1016/j.addma.2024.104136.

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Wei, Xueying, Ingolf Behm, Tony Winkler e Rüdiger Bähr. "Optimization of extrusion-based additive manufacturing of bronze metal parts using a CuSn10/Polylactic acid composite". Journal of Materials Research and Technology 30 (maggio 2024): 3602–10. http://dx.doi.org/10.1016/j.jmrt.2024.04.111.

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Rosnitschek, Tobias, Andressa Seefeldt, Bettina Alber-Laukant, Thomas Neumeyer, Volker Altstädt e Stephan Tremmel. "Correlations of Geometry and Infill Degree of Extrusion Additively Manufactured 316L Stainless Steel Components". Materials 14, n. 18 (9 settembre 2021): 5173. http://dx.doi.org/10.3390/ma14185173.

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Abstract (sommario):

This study focuses on the effect of part geometry and infill degrees on effective mechanical properties of extrusion additively manufactured stainless steel 316L parts produced with BASF’s Ultrafuse 316LX filament. Knowledge about correlations between infill degrees, mechanical properties and dimensional deviations are essential to enhance the part performance and further establish efficient methods for the product development for lightweight metal engineering applications. To investigate the effective Young’s modulus, yield strength and bending stress, standard testing methods for tensile testing and bending testing were used. For evaluating the dimensional accuracy, the tensile and bending specimens were measured before and after sintering to analyze anisotropic shrinkage effects and dimensional deviations linked to the infill structure. The results showed that dimensions larger than 10 mm have minor geometrical deviations and that the effective Young’s modulus varied in the range of 176%. These findings provide a more profound understanding of the process and its capabilities and enhance the product development process for metal extrusion-based additive manufacturing.

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