Process maps and models for binder jetting additive manufacturing of low cost alloys

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Metal additive manufacturing (AM) has recently seen a significant growth in both use and capabilities, with an increased adoption in industrial and consumer markets. The prohibitive challenges in this space remain cost of technology adoption, as well as the reliable production of high quality defect-free parts. To tackle these challenges, the project focus will be on (1) lowering the cost barriers by deploying powder bed binder jetting (PBBJ) using low cost water atomized alloy steels AISI 4340 (0.4C-0.7Mn-0.25Si-1.8Ni-0.8Cr-0.25Mo) and FL4401 (0.15Mn-0.85Mo) +0.6C and (2) enabling robust and fast process parameter selection via modeling approaches and robust validation for desired product quality outcomes. The overall objective of the project is to demonstrate that metal AM via PBBJ can be deployed as a low-cost and reliable alternative to metal part production with a direct application to the spare parts market and automotive industry. This study will be conducted in close collaboration with Rio Tinto, QC, Canada, a leading metals and mining company involved in the manufacture of metal powders. The methodology to achieve the proposed objective will be to deploy three work packages. Firstly, a PBBJ process window will be developed through a design of experiments (DoE) procedure. The process variables of interest will be studied, and custom designed artifacts will be manufactured to test green part performance. The process window will also be predicted using newly-proposed green part density models. The second package will focus on post-process parameter window development, whereby several post-process variables such as de-binding and sintering will be studied for the materials of interest. Part quality will be analyzed via computed tomography scans, surface profilometry and mechanical testing. A final part density predictive model (sinter curve) will be developed through dilatometry analysis that will map process variables to final part density. The third and final work package will focus on functional product design and manufacturing. Standard artifacts will be developed to quantify design features specific to PBBJ. A series of automotive and industrial product designs will be fabricated and tested.