Abstract
Metal fused filament fabrication (MF3) combines fused filament fabrication and sintering processes to fabricate complex metal components. In MF3, powder-polymer mixtures are printed to produce green parts that are subsequently debound and sintered. In the design for MF3 (DfMF3), it is important to understand how material properties of the filament affect processability, part quality, and ensuing properties. However, the materials property database of powder-polymer materials to perform DfMF3 simulations is very limited, and experimental measurements can be expensive and time-consuming. This work investigates models that can predict the powder-polymer material properties that are required as input parameters for simulating the MF3 using the Digimat-AM® process design platform for fused filament fabrication. Ti-6Al-4V alloy (56–60 vol.%) and a multicomponent polymer binder were used to predict properties such as density, specific heat, thermal conductivity, Young’s modulus, and viscosity. The estimated material properties were used to conduct DfMF3 simulations to understand material-processing-geometry interactions.
Similar content being viewed by others
References
J. Gonzalez-Gutierrez, S. Cano, S. Schuschnigg, C. Kukla, J. Sapkota, and C. Holzer, Materials 11, 840 (2018).
R.M. German, Injection molding of metals and ceramics, 1st ed. (Princeton: Metal Powder Industries Federation, 1997), pp. 83–98.
S. Rangarajan, G. Qi, N. Venkataraman, A. Safari, and S.C. Danforth, J. Am. Ceram. Soc. 83, 1663 (2000).
G. Wu, N.A. Langrana, R. Sadanji, and S. Danforth, Mater. Des. 23, 97 (2002).
W. Lengauer, I. Duretek, M. Fürst, V. Schwarz, J. Gonzalez-Gutierrez, S. Schuschnigg, C. Kukla, M. Kitzmantel, E. Neubauer, and C. Lieberwirth, Int. J. Refract. Met. Hard Mater. 82, 141 (2019).
S. Masood and W. Song, Mater. Des. 25, 587 (2004).
M. Nikzad, S. Masood, and I. Sbarski, Mater. Des. 32, 3448 (2011).
D.A. Anderegg, H.A. Bryant, D.C. Ruffin, S.M. Skrip Jr, J.J. Fallon, E.L. Gilmer, and M.J. Bortner, Addit. Manuf. 26, 76 (2019).
M.K. Agarwala, V.R. Jamalabad, N.A. Langrana, A. Safari, P.J. Whalen, and S.C. Danforth, Rapid Prototyp. J. 2, 4 (1996).
A. Bose, C.A. Schuh, J.C. Tobia, N. Tuncer, N.M. Mykulowycz, A. Preston, A.C. Barbati, B. Kernan, M.A. Gibson, and D. Krause, Int. J. Refract. Met. Hard Mater. 73, 22 (2018).
J. Gonzalez-Gutierrez, F. Arbeiter, T. Schlauf, C. Kukla, and C. Holzer, Mater. Lett. 248, 165 (2019).
B. Barmore, Fused Filament Fabrication of Filled Polymers for Metal Additive Manufacturing. Master’s Thesis (Mechanical Engineering, Oregon State University, 2016), pp. 55–60.
L. Ren, X. Zhou, Z. Song, C. Zhao, Q. Liu, J. Xue, and X. Li, Materials 10, 305 (2017).
e-xstream, Digimat-AM simulation solution for Additive Manufacturing. https://www.e-xstream.com/product/digimat-am. Accessed 30 July 2019.
Alphastar, Genoa Additive Manufacturing design tool and software suite for polymers, metals and ceramics. http://www.alphastarcorp.com/products/genoa-3dp-simulation/. Accessed 30 July 2019.
Vanderplaats, Genesis structural analysis and optimization software. http://www.vrand.com/products/genesis/. Accessed 30 July 2019.
L.E. Nielsen, Predicting the Properties of Mixtures, 1st ed. (New York: M. Dekker, 1978), pp. 5–11.
S. McGee and R. McGullough, Polym. Compos. 2, 149 (1981).
W. Wu, K. Sadeghipour, K. Boberick, and G. Baran, Mater. Sci. Eng. A 332, 362 (2002).
T.J. Wooster, S. Abrol, J.M. Hey, and D.R. MacFarlane, Compos. Part A 35, 75 (2004).
I. Balać, M. Milovančević, C.-Y. Tang, P.S. Uskoković, and D.P. Uskoković, Mater. Lett. 58, 2437 (2004).
Y.P. Mamunya, V. Davydenko, P. Pissis, and E. Lebedev, Eur. Polym. J. 38, 1887 (2002).
L. Kowalski, J. Duszczyk, and L. Katgerman, J. Mater. Sci. 34, 1 (1999).
A. Boudenne, L. Ibos, M. Fois, E. Gehin, and J.C. Majeste, J. Polym. Sci. Part B Polym. Phys. 42, 722 (2004).
T. Zhang, J. Evans, and K. Dutta, J. Eur. Ceram. Soc. 5, 303 (1989).
K.H. Kate, R.K. Enneti, S.-J. Park, R.M. German, and S.V. Atre, Crit. Rev. Solid State Mater. Sci. 39, 197 (2014).
K.H. Kate, R.K. Enneti, V.P. Onbattuvelli, and S.V. Atre, Ceram. Int. 39, 6887 (2013).
K.H. Kate, V.P. Onbattuvelli, R.K. Enneti, S.W. Lee, S.J. Park, and S.V. Atre, JOM 64, 1048 (2012).
K.H. Kate, R.K. Enneti, T. McCabe, and S.V. Atre, Ceram. Int. 42, 194 (2016).
N.M. Nor, N. Muhamad, M. Ibrahim, M. Ruzi, and K. Jamaludin, Int. J. Mech. Mater. Eng. 6, 126 (2011).
G. Shibo, Q. Xuanhui, H. Xinbo, Z. Ting, and D. Bohua, J. Mater. Process. Technol. 173, 310 (2006).
G. Obasi, O. Ferri, T. Ebel, and R. Bormann, Mater. Sci. Eng. A 527, 3929 (2010).
E. Ergül, H. Özkan Gülsoy, and V. Günay, Powder Metall. 52, 65 (2009).
H.Ö. Gülsoy, N. Gülsoy, and R. Calışıcı, Bio-Med. Mater. Eng. 24, 1861 (2014).
K.C. Mills, Recommended Values of Thermophysical Properties for Selected Commercial Alloys (Cambridge: Woodhead Publishing, 2002), pp. 211–215.
G. Welsch, R. Boyer, and E. Collings, Materials Properties Handbook: Titanium Alloys (Ohio: ASM International, 1993), pp. 514–520.
R. Enneti, V. Onbattuvelli, O. Gulsoy, K. Kate, and S. Atre, Powder-Binder Formulation and Compound Manufacture in Metal Injection Molding (MIM). Handbook of Metal Injection Molding, 2nd ed. (Cambridge: Woodhead Publishing, 2002), pp. 57–88.
G. Chen, C. Ren, X. Yang, X. Jin, and T. Guo, Int. J. Adv. Manuf. Technol. 56, 1027 (2011).
C.J. Smithells, Metals Reference Book, 5th ed. (Oxford: Butterworth Publishing, 1976), pp. 1148–1152.
V. Wagner, M. Baili, G. Dessein, and D. Lallement, Key Eng. Mater. 446, 147 (2010).
J. Elmer, T. Palmer, S. Babu, and E. Specht, Mater. Sci. Eng. A 391, 104 (2005).
R. Rai, J. Elmer, T. Palmer, and T. DebRoy, J. Phys. D Appl. Phys. 40, 5753 (2007).
M. Niinomi, Mater. Sci. Eng. A 243, 231 (1998).
Y. Lee and G. Welsch, Mater. Sci. Eng. A 128, 77 (1990).
Y.P. Wu, Q.-X. Jia, D.-S. Yu, and L.-Q. Zhang, Polym. Test. 23, 903 (2004).
C.L. Tucker and E. Liang, Compos. Sci. Technol. 59, 655 (1999).
C. Wong and R.S. Bollampally, J. Appl. Polym. Sci. 74, 3396 (1999).
A. Metzner, J. Rheol. 29, 739 (1985).
R.M. German, J. Am. Ceram. Soc. 77, 283 (1994).
H. Chiang, C. Hieber, and K. Wang, Polym. Eng. Sci. 31, 116 (1991).
A.H. Peng, Adv. Mater. Res. 538–541, 1564 (2012).
B.N. Turner and S.A. Gold, Rapid Prototyp. J. 21, 250 (2015).
Acknowledgement
The authors acknowledge financial assistance from the Minority Business Development Agency of the US Department of Commerce as well as NASA through a subcontract from Techshot. The authors also acknowledge MSC Software, AlphaSTAR, and Vanderplaats R&D for their support in providing AM software platforms.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Electronic supplementary material
Below is the link to the electronic supplementary material.
Rights and permissions
About this article
Cite this article
Singh, P., Shaikh, Q., Balla, V.K. et al. Estimating Powder-Polymer Material Properties Used in Design for Metal Fused Filament Fabrication (DfMF3). JOM 72, 485–495 (2020). https://doi.org/10.1007/s11837-019-03920-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11837-019-03920-y