Experimental Study on Metal Parts under Variable 3D Printing and Sintering Orientations Using Bronze/PLA Hybrid Filament Coupled with Fused Filament Fabrication
Abstract
:1. Introduction
2. Materials and Methods
2.1. Materials
2.2. 3D Printing
2.3. Thermal Debinding and Sintering
2.4. Printing and Sintering Direction
2.4.1. Printing and Sintering Direction for Cubes
2.4.2. Printing and Sintering Directions for Tensile Specimens
2.5. Shrinkage and Density Analysis
2.6. Microstructural Characterization
2.7. Mechanical Characterization
3. Results and Discussion
3.1. Shrinkage and Density Analysis through Sintered Cubes
3.2. Tensile Stress and Porosity Analysis through Tensile Specimens
3.2.1. Tensile Stress Analysis
3.2.2. Microstructural and Porosity Analysis
4. Conclusions
- Sintering orientations had only minor effects on shrinkage, density, and porosity. The results from different sintering directions were similar. Shrinkage in the layer direction was lower than in the x and y directions. The density of the parts was increased by about 6.6 g/cm3 after sintering. The porosity was independent of the sintering direction. Parts produced in the “upright” sintering direction resulted in weakness leading to fracturing.
- The printing orientations played an important role in tensile stress and porosity. “Upright” printed specimens were weak. Conversely, “on-edge” printed specimens had the best tensile stress at about 190 MPa. In addition, porosity occurred on the surfaces of the parts that were parallel to the printing bed. The pore volume was dependent on the area of the horizontally printed surfaces.
- The best printing-sintering combination was “on-edge-flat”. The tensile stress and surface porosity supported these conclusions.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Composition | Metal | Synthetic Material | ||||
---|---|---|---|---|---|---|
Copper | Tin | Phosphorous | PLA | 2-Propenenitrile, Polymer with 1,3-Butadiene and Ethenylbenzene | Binding Additive | |
Content (wt. %) | 75.99 | 8.84 | 0.17 | 15 | trace | trace |
Parameter | Unit | Value |
---|---|---|
Nozzle diameter | mm | 0.6 |
Layer thickness (first layer) | mm | 0.2 |
Layer thickness (left layers) | mm | 0.3 |
Nozzle temperature (first layer) | °C | 215 |
Nozzle temperature (left layers) | °C | 210 |
Printing bed temperature | °C | 60 |
Infill percentage | % | 100 |
Flow degree | % | 100 |
Printing speed | mm/s | 70 |
Extrusion rate | mm3/s | 4.9 |
Test Number | Printing Direction | Sintering Direction |
---|---|---|
1 | Flat | Flat |
2 | Flat | On-edge |
3 | Flat | Upright |
4 | On-edge | Flat |
5 | On-edge | On-edge |
6 | On-edge | Upright |
7 | Upright | Flat |
8 | Upright | On-edge |
9 | Upright | Upright |
Sintering Direction | Dimension Shrinkage (%) | Weight Shrinkage (%) | Density (g/cm3) | |||
---|---|---|---|---|---|---|
x-Axis | y-Axis | z-Axis | Before Sintering | After Sintering | ||
On xy surface | 20.82 | 19.58 | 14.43 | 14.7 | 3.72 | 6.93 |
On xz surface | 20.01 | 21.61 | 11.74 | 15.42 | 3.7 | 6.61 |
On yz surface | 21.21 | 20.08 | 11.53 | 15.19 | 3.72 | 6.56 |
On-edge | 21.18 | 21.61 | 12.82 | 14.84 | 3.71 | 6.63 |
On point | 20.37 | 20.52 | 13.6 | 14.78 | 3.7 | 6.53 |
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Wei, X.; Behm, I.; Winkler, T.; Scharf, S.; Li, X.; Bähr, R. Experimental Study on Metal Parts under Variable 3D Printing and Sintering Orientations Using Bronze/PLA Hybrid Filament Coupled with Fused Filament Fabrication. Materials 2022, 15, 5333. https://doi.org/10.3390/ma15155333
Wei X, Behm I, Winkler T, Scharf S, Li X, Bähr R. Experimental Study on Metal Parts under Variable 3D Printing and Sintering Orientations Using Bronze/PLA Hybrid Filament Coupled with Fused Filament Fabrication. Materials. 2022; 15(15):5333. https://doi.org/10.3390/ma15155333
Chicago/Turabian StyleWei, Xueying, Ingolf Behm, Tony Winkler, Stefan Scharf, Xujun Li, and Rüdiger Bähr. 2022. "Experimental Study on Metal Parts under Variable 3D Printing and Sintering Orientations Using Bronze/PLA Hybrid Filament Coupled with Fused Filament Fabrication" Materials 15, no. 15: 5333. https://doi.org/10.3390/ma15155333