CAREER: Powder Preparation and Compaction for Ceramic Binder Jet Additive Manufacturing

职业：陶瓷粘合剂喷射增材制造的粉末制备和压实

• 批准号: 2047908
• 负责人: Chao Ma
• 金额: $ 58万
• 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: 2021
• 资助国家: 美国
• 起止时间: 2021-07-01 至 2023-11-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2047908&HistoricalAwards=false
• 关键词: CAREER; Powder; Preparation; Compaction; Ceramic

This Faculty Early Career Development (CAREER) grant supports fundamental research that will generate knowledge related to ceramic binder jet additive manufacturing, promoting the progress of science and resulting in beneficial societal impacts. Advanced ceramic materials play a vital role in numerous applications with strict requirements or under harsh conditions, such as those in the biomedical, aerospace, chemical, and energy industries. Traditional manufacturing methods for ceramic parts have severe geometric constraints, long production time, and high cost. Binder jet additive manufacturing can overcome these drawbacks. However, it is currently unable to produce dense ceramic parts, significantly limiting its applications. This research aims to increase understanding of how powder granule characteristics (density, structure, and strength) and powder compaction affect resulting part density. In addition, this CAREER plan includes a series of education activities to strengthen and diversify the advanced manufacturing workforce, impacting K-12 teachers and students, undergraduate and graduate students, and professionals in the industry.The goal of this research is to enable a new density improvement approach for ceramic binder jet additive manufacturing, using a tailored feedstock powder and an emerging powder bed formation method. The feedstock powder consists of granules composed of numerous nanoparticles that are weakly bonded together. In the powder bed formation method, compaction is performed after spreading each layer of powder. It is hypothesized that the required compaction pressure to achieve dense ceramic parts is affected by granule characteristics in the following manners: (1) granules with a low density require a lower pressure to fracture or plastically deform (a positive effect), but have a lower initial packing density (a negative effect); (2) granules with a porous structure can be more easily fractured or plastically deformed, but have more initial intragranular pores; (3) granules with a low strength can also be more easily fractured or deformed, but have a reduced initial granule rearrangement. Experimental research will be conducted to identify the tradeoffs associated with each granule characteristic and to determine the conditions under which its positive or negative effect is dominant. Afterward, numerical simulation at the granule and nanoparticle scales will be performed to explain the experimental results and to provide physical insights on underlying compaction mechanisms. This research will generate new knowledge about compaction of multiple thin layers of granules that is critical to binder jet additive manufacturing.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.

该学院早期职业发展（CAREER）补助金支持基础研究，这些研究将产生与陶瓷粘合剂喷射增材制造相关的知识，促进科学进步并产生有益的社会影响。先进陶瓷材料在许多要求严格或条件恶劣的应用中发挥着至关重要的作用，例如生物医学、航空航天、化学和能源行业。陶瓷零件的传统制造方法具有严格的几何约束、生产时间长、成本高。粘合剂喷射增材制造可以克服这些缺点。然而，它目前无法生产致密的陶瓷零件，极大地限制了其应用。这项研究旨在加深对粉末颗粒特性（密度、结构和强度）和粉末压实如何影响最终零件密度的了解。此外，该职业计划还包括一系列教育活动，旨在加强先进制造劳动力并使其多样化，影响K-12教师和学生、本科生和研究生以及行业专业人士。这项研究的目标是使用定制的原料粉末和新兴的粉末床形成方法，为陶瓷粘合剂喷射增材制造提供一种新的密度改进方法。原料粉末由颗粒组成，颗粒由许多弱结合在一起的纳米颗粒组成。在粉末床形成方法中，在铺展每层粉末后进行压实。据推测，获得致密陶瓷部件所需的压实压力受颗粒特性的影响如下：（1）低密度颗粒需要较低的压力来破裂或塑性变形（正面影响），但初始堆积密度较低（负面影响）； (2)具有多孔结构的颗粒更容易破裂或塑性变形，但初始颗粒内孔较多； (3)强度低的颗粒也更容易破裂或变形，但初始颗粒重排减少。将进行实验研究，以确定与每种颗粒特性相关的权衡，并确定其积极或消极影响占主导地位的条件。随后，将进行颗粒和纳米颗粒尺度的数值模拟，以解释实验结果并提供对潜在压实机制的物理见解。这项研究将产生关于多个薄层颗粒压实的新知识，这对于粘合剂喷射增材制造至关重要。该奖项反映了 NSF 的法定使命，并通过使用基金会的智力优点和更广泛的影响审查标准进行评估，被认为值得支持。

项目成果

Combining powder bed compaction and nanopowders to improve density in ceramic binder jetting additive manufacturing

• DOI: 10.1016/j.ceramint.2021.09.077
• 发表时间: 2021-09
• 期刊: Ceramics International
• 影响因子: 5.2
• 作者: Mohammadamin Moghadasi;Guanxiong Miao;Ming Li;Z. Pei;Chao Ma

Binder Jetting Additive Manufacturing: The Effect of Feed Region Density on Resultant Densities

粘合剂喷射增材制造：进料区域密度对最终密度的影响

• DOI: 10.1115/1.4054453
• 发表时间: 2022
• 期刊: Journal of Manufacturing Science and Engineering
• 作者: Porter, Quinton;Li, Ming;Pei, Zhijian;Ma, Chao
• 通讯作者: Ma, Chao