Photopolymerization of Stainless Steel 420 Metal Suspension: Printing System and Process Development of Additive Manufacturing Technology toward High-Volume Production
Abstract
:1. Introduction
1.1. Binder Jet Printing
1.2. Stereolithography
1.3. SEAM Process Overview
- Step 1: A photosensitive suspension, which consists of metal powder and photopolymer resin, is formulated. The suspension properties must satisfy several criteria: high powder volume loading and appropriate viscosity to be processable in a layer-by-layer fashion using SLA techniques.
- Step 2: The suspension is shaped into three-dimensional (3D) green parts using the basic SLA technique. In a layer-by-layer fashion, ultraviolet (UV) light is selectively irradiated onto the suspension surface, which induces photopolymerization of the resin. The cured resin acts as a binder, holding the metal particles together, forming the desired 2D layer geometry. The irradiation patterns are extracted from the 3D CAD models, similar to other AM techniques.
- Step 3: The formed 3D geometry or green part is then subjected to appropriate thermal treatments for binder removal and high-temperature sintering in the same manner as the BJP process to achieve the final solid metal object.
2. Development of the SEAM Printing System
2.1. Design Challenges and Considerations
- The suspension must be kept homogeneous during the printing process. A mixing system capable of dispensing the suspension onto the printing platform layer by layer should be utilized;
- A top-down system design is preferred due to the weaker inter-layer bonding strength of the suspension layer. Moreover, the gravitational force acting on the printed part is against the printing direction in the bottom-up design, which can lead to layer delamination with a significant part size and weight;
- A dynamic mask curing system is desirable to ensure high printing speed as well as layer uniformity. However, the curing system must be carefully chosen to ensure adequate UV light intensity for initiating photopolymerization of the suspension.
2.2. Proof-of-Concept Experiments
2.2.1. Materials and Methods
2.2.2. Physical Mask Experiment
- Experimental Setup
- Result and Discussion
2.2.3. Modified SLA System Experiment
- Experimental Setup
- Result and Discussion
2.2.4. Modified DLP Projector Experiment
- Experimental Setup
- Results and Discussion
2.3. First-Generation Prototype of SEAM
3. Green Part Fabrication
3.1. Suspension Formulation
- An amount of 100 g of each powder size is tapped for 20 min at 150 rpm up to five times in a graduated cylinder using a powder tapping device. The tapped packing density of the powder is taken as the average of all measurements;
- The calculated tapped density of each powder is used as input to the code to determine the optimal packing ratio;
- The different powder sizes combined based on the obtained packing ratio can be mixed using a high-speed mixer or a benchtop ball mill.
3.2. Printing Strategy
3.3. Processing Parameters
3.4. Fabricated Green Parts
4. Sintering SEAM-Printed SS420 Parts to Full Density
4.1. Previous Related Work
4.2. Experimental Setup
- From a compositional perspective, the SEAM and BJP parts should be identical after a complete removal of the binder except for two main differences:
- Initial powder packing density: the powder used in BJP is typically composed of multiple sizes with a high small/large particle radius ratio to achieve a higher packing density. By combining three different powder sizes with the average diameters of 82, 14, and 4 µm, a powder mixture with a packing density of 63.87% was produced for BJP. Several other studies also indicate the possibility of attaining a powder packing density of above 70% for BJP parts by including small powder particles of 5 µm and below [36,41]. On the other hand, the addition of the smallest powder particles significantly limits the curing depth of the suspension;
- Actual powder packing density in the feedstock: the powder feedstock used in BJP is the as-produced multi-sized powder mixture. As the material is spread on the printing platform, the particles are loosely packed but in contact with each other. In contrast, the feedstock used for the SEAM process is a mixture of metal powder and liquid photopolymer, typically at a 50–60 vol% of metal particles. Therefore, the interstitial spaces among the metal powder particles are filled with liquid photopolymer, resulting in an increase in inter-particle spacing. While the initial powder packing density is conserved as the green body densifies and shrinks during the sintering process, the initial inter-particle gap is inevitably higher in SEAM-printed parts in comparison to BJP-printed parts.
4.3. Results and Discussion
5. Potential of the SEAM Process as a High-Volume Production AM Technology
- In terms of the initial capital cost, both PBF and SEAM processes require high-temperature furnaces to attain stress relief for PBF processes [55] or to enable sintering for SEAM. However, PBF printing systems themselves are well-known to be extremely costly due to their complexity in design as well as the use of an expensive laser or electron beam melting system which also requires accurate position control [21]. On the other hand, with its design simplicity and the utilization of an affordable DLP projection curing module, the SEAM printing system can be constructed for a fraction of the cost of PBF systems;
- For fabrication cost, PBF processes follow a linear cost model with respect to fabrication time as part quantity or volume increases, i.e., the more parts or the larger the part geometry, the longer the time required for fabrication, which translates to higher energy consumption and cost. The SEAM process offers a significant reduction in fabrication time, as its layer generation time is independent of the number of parts and layer geometry complexity or size. Moreover, the SEAM process offers a significant cost advantage in fabricating multiple parts simultaneously, due to the ability of debinding and sintering multiple parts in the same heating cycle, which can significantly reduce the energy consumption. Additionally, in situations where the target components require joining of multiple sub-components, the SEAM process also offers the unique ability to co-debind and co-sinter multiple green parts together in a single heating cycle to achieve the final joined and assembled components [46]. Producing the same assembled components using PBF processes requires not only the fabrication of sub-components, followed by necessary post-processing steps, but also a final mechanical joining and sealing, which further increases both the total time and cost of the manufacturing process;
- For post-processing operations, as-built parts fabricated by laser beam powder bed fusion (PBF-LB) require heat treatment for residual stress relief and several following surface finishing steps to attain a desirable surface quality [52]. On the other hand, due to the isothermal consolidation environment, as-built parts fabricated by the SEAM process are residual stress-free without additional heat treatment to relieve residual stress or microstructure homogenization. While a few studies have recommended a subsequent step of isostatic hot pressing after the sintering process to further eliminate residual pores, this research will demonstrate the feasibility of achieving fully dense parts with a single sintering cycle. With regard to surface finish, parts produced by furnace sintering and especially sintering in the presence of liquid phase are superior to laser-printed parts [56,57]. As the initial surface roughness plays a critical role in determining the required number of subsequent surface finishing steps of the parts [58,59,60], the SEAM process offers time and cost reductions in attaining the desired final surface quality.
6. Conclusions
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Photopolymer Resin | Form | Viscosity | Density at Ambient Temperature | Modulus (After Curing) | Recommended Curing Wavelength |
---|---|---|---|---|---|
CPS3010 | Liquid | 12cP | 1.12 g/mL | 685 Mpa | 320–500 nm |
Projector Name | Light Source | DMD Chip | Uniformity (%) | Projection Screen Size (m) |
---|---|---|---|---|
Optoma S343 DLP Projector | 203 W metal-halide lamp | Texas Instruments SVGA DMD | 80 | 0.7–7.73 |
Additive Addition (wt.%) | |||||
---|---|---|---|---|---|
0.45 | 0.5 | 0.55 | 0.6 | ||
Sintering Temperature (°C) | 1200 | A1 | B1 | C1 | D1 |
1250 | A2 | B2 | C2 | D2 | |
1300 | A3 | B3 | C3 | D3 |
Additive Addition (wt.%) | |||||
---|---|---|---|---|---|
0.45 | 0.5 | 0.55 | 0.6 | ||
Sintering Temperature (°C) | 1240 | 98.21 | 98.92 | 99.25 | 99.53 |
1250 | 99.69 | 99.04 | 99.62 | 99.73 | |
1260 | 99.25 | 99.53 | 99.71 | 99.81 |
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Nguyen, H.X.; Poudel, B.; Qu, Z.; Kwon, P.; Chung, H. Photopolymerization of Stainless Steel 420 Metal Suspension: Printing System and Process Development of Additive Manufacturing Technology toward High-Volume Production. J. Manuf. Mater. Process. 2024, 8, 191. https://doi.org/10.3390/jmmp8050191
Nguyen HX, Poudel B, Qu Z, Kwon P, Chung H. Photopolymerization of Stainless Steel 420 Metal Suspension: Printing System and Process Development of Additive Manufacturing Technology toward High-Volume Production. Journal of Manufacturing and Materials Processing. 2024; 8(5):191. https://doi.org/10.3390/jmmp8050191
Chicago/Turabian StyleNguyen, Hoa Xuan, Bibek Poudel, Zhiyuan Qu, Patrick Kwon, and Haseung Chung. 2024. "Photopolymerization of Stainless Steel 420 Metal Suspension: Printing System and Process Development of Additive Manufacturing Technology toward High-Volume Production" Journal of Manufacturing and Materials Processing 8, no. 5: 191. https://doi.org/10.3390/jmmp8050191