Binder Jet Additive Manufacturing with Granulated Ceramic Powders

使用粒状陶瓷粉末进行粘合剂喷射增材制造

• 批准号: 1762341
• 负责人: Zhijian Pei
• 金额: $ 39.09万
• 依托单位: Texas A&M Engineering Experiment Station
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2018
• 资助国家: 美国
• 起止时间: 2018-08-01 至 2023-07-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1762341&HistoricalAwards=false
• 关键词: Binder; Jet; Additive; Manufacturing; Granulated

Currently, ceramic parts made by binder jet additive manufacturing have low density and poor mechanical properties; this award supports fundamental research addressing the use of granulated ceramic nanopowder for binder jet additive manufacturing to address these shortcomings. Nanoparticles are difficult to incorporate into the most common additive manufacturing approaches, but the use of granulations of ceramic nanoparticles with binders allows the use of nanoparticles without the normal drawbacks of limited spreadability. A granulated nanoparticle consists of nanoparticles combined with a polymer binder, which is then machined or milled to produce a particle a few tens of micrometers in diameter, which contains many nanoparticles. This allows the use of granulations without complicating spreading of powder in an additive manufacturing machine, and the use of nanoparticles to produce denser, stronger parts in additive manufacturing. Research results from this project will help enable additive manufacturing of high-density ceramic parts to produce wear-resistant parts economically. The ultimate application in mind is next-generation orthopedic implants, which is an economic area of great importance to the US. In addition, there are spillover applications in the aerospace, defense and automotive sectors, so that this proposal directly and positively impacts economic welfare and national security. The research will involve undergraduate and graduate students, including those from the underrepresented groups, who will conduct experiments and analyze experimental results. The research objective is to test three sets of hypotheses: (1) granulated powder leads to a higher printed and sintered density than both nanopowder and micropowder; (2) granulated powder has a similar flowability to micropowder but a higher flowability than nanopowder; and (3) granulated powder has a similar sinterability to nanopowder but a higher sinterability than micropowder. The first set of hypotheses will be tested by measuring the densities of printed and sintered samples from the three powders (granulated powder, nanopowder, and micropowder) with Archimedes' method and statistically comparing the results. The second set of hypotheses will be tested by comparing the Hausner ratios (the ratio between tap and apparent densities of each powder) of the three powders. The third set of hypotheses will be tested by comparing the achieved densities of the three powders by a traditional pressing and sintering means. Testing these three sets of hypotheses will result in new knowledge about effects of granulation on binder jet additive manufacturing, and flowing and sintering behaviors of granulated powder, nanopowder, and micropowder.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

目前，由粘合喷气添加剂制造制造的陶瓷零件具有低密度和机械性能较差。该奖项支持基础研究，该研究涉及使用颗粒状的陶瓷纳米纸用于粘合喷气添加剂制造的使用，以解决这些缺点。纳米颗粒很难将其纳入最常见的添加剂制造方法中，但是使用陶瓷纳米颗粒的颗粒与粘合剂的使用允许使用纳米颗粒，而无需有限的散布性。颗粒状的纳米颗粒由结合聚合物粘合剂的纳米颗粒组成，然后将其加工或铣削以产生直径几十微米的粒子，其中包含许多纳米颗粒。这允许使用颗粒，而不会复杂化添加剂机器中的粉末，并使用纳米颗粒在添加剂制造中产生更密集，更强的零件。该项目的研究结果将有助于实现高密度陶瓷零件的添加剂制造，从而在经济上产生耐磨性零件。考虑到最终的应用是下一代骨科植入物，这对美国来说是一个非常重要的经济领域。此外，在航空航天，国防和汽车部门中还有溢出申请，因此该提案直接和积极地影响了经济福利和国家安全。这项研究将涉及本科生和研究生，包括来自代表性不足的群体的研究生，他们将进行实验并分析实验结果。研究目标是检验三组假设：（1）颗粒粉末的印刷密度和烧结密度高于纳米库和微孔。 （2）粒状粉末与微孔的流动性相似，但流动性比纳米库更高。 （3）颗粒粉具有与纳米盘相似的缩略性，但比微波德更高。第一组假设将通过测量来自Archimedes的方法的三个粉末（粒状粉末，纳米脂和微量流）的印刷和烧结样品的密度来测试，并统计地比较结果。第二组假设将通过比较三个粉末的Hausner比率（每种粉末的Tap和明显密度之间的比率）进行测试。第三组假设将通过通过传统的紧迫和烧结手段比较三个粉末的密度来检验。测试这三组假设将导致有关颗粒对粘合喷气添加剂制造的影响的新知识，以及粒状粉末，纳米福德和微量流粉的流动和烧结行为。该奖项反映了NSF的法定任务，并被认为是通过基金会的知识优点和广泛的crietia crietia crietia crietia crietia crietia criteria crietia criteria crietia crietia crietia criteria criperia criteria criperia criperia recectia receptia rectuniation。

项目成果

Ceramic binder jetting additive manufacturing: Effects of granulation on properties of feedstock powder and printed and sintered parts

• DOI: 10.1016/j.addma.2020.101542
• 发表时间: 2020-12-01
• 期刊: ADDITIVE MANUFACTURING
• 影响因子: 11
• 作者: Miao, Guanxiong;Du, Wenchao;Ma, Chao
• 通讯作者: Ma, Chao

Difference between powder bed density and green density for a free-flowing powder in binder jetting additive manufacturing

• DOI: 10.1016/j.jmapro.2022.10.030
• 发表时间: 2022-12
• 期刊: Journal of Manufacturing Processes
• 影响因子: 6.2
• 作者: Ming Li;Guanxiong Miao;W. Du;Z. Pei;Chao Ma

Binder Jetting Additive Manufacturing: Powder Packing in Shell Printing

• DOI: 10.3390/jmmp7010004
• 发表时间: 2022-12
• 期刊: Journal of Manufacturing and Materials Processing
• 影响因子: 3.2
• 作者: Guanxiong Miao;Mohammadamin Moghadasi;Ming Li;Z. Pei;Chao Ma

Metal Binder Jetting Additive Manufacturing: A Literature Review

• DOI: 10.1115/1.4047430
• 发表时间: 2020-09-01
• 期刊: JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
• 影响因子: 4
• 作者: Li, Ming;Du, Wenchao;Ma, Chao
• 通讯作者: Ma, Chao

Experimental investigation on the effect of roller traverse and rotation speeds on ceramic binder jetting additive manufacturing

• DOI: 10.1016/j.jmapro.2022.05.039
• 发表时间: 2022-07
• 期刊: Journal of Manufacturing Processes
• 影响因子: 6.2
• 作者: Guanxiong Miao;Mohammadamin Moghadasi;W. Du;Z. Pei;Chao Ma