Elastomers and Composites

The Rubber Society of Korea (한국고무학회)
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Fused Deposition Modeling of Iron-alloy using Carrier Composition

  • Harshada R. Chothe (Department of Materials Engineering and Convergence Technology, RIGET, Gyeongsang National University) ;
  • Jin Hwan Lim (Department of Materials Engineering and Convergence Technology, RIGET, Gyeongsang National University) ;
  • Jung Gi Kim (Department of Materials Engineering and Convergence Technology, RIGET, Gyeongsang National University) ;
  • Taekyung Lee (School of Mechanical Engineering, Pusan National University) ;
  • Taehyun Nam (Department of Materials Engineering and Convergence Technology, RIGET, Gyeongsang National University) ;
  • Jeong Seok Oh (Department of Materials Engineering and Convergence Technology, RIGET, Gyeongsang National University)
  • Received : 2023.02.27
  • Accepted : 2023.03.13
  • Published : 2023.03.31
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Abstract

Additive manufacturing (AM) or three-dimensional (3D) printing of metals has been drawing significant attention due to its reliability, usefulness, and low cost with rapid prototyping. Among the various AM technologies, fused deposition modeling (FDM) or fused filament fabrication is receiving much interest because of its simple manufacturing processing, low material waste, and cost-effective equipment. FDM technology uses metal-filled polymer filaments for 3D printing, followed by debinding and sintering to fabricate complex metal parts. An efficient binder is essential for producing polymer filaments and the thermal post-processing of printed objects. This study involved an in-depth investigation of and a fabrication route for a novel multi-component binder system with steel alloy powder (45 vol.%) ranging from filament fabrication and 3D printing to debinding and sintering. The binder system consisted of polyvinyl pyrrolidone (PVP) as a binder and thermoplastic polyurethane (TPU) and polylactic acid (PLA) as a carrier. The PVP binder held the metal components tightly by maintaining their stoichiometry, and the TPU and PLA in the ratio of 9:1 provided flexibility, stiffness, and strength to the filament for 3D printing. The efficacy of the binder system was examined by fabricating 3D-printed cubic structures. The results revealed that the thermal debinding and sintering processes effectively removed the binder/carrier from the cubic structures, resulting in isotropic shrinkage of approximately 15.8% in all directions. The scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX) patterns displayed the microstructure behavior, phase transition, and elemental composition of the 3D cubic structure.

Keywords

Acknowledgement

This work was supported by the National Research Foundation of Korea (NRF) grant funded by the Korean Government (MSIT) (2020R1A4A3079417) and the Development Fund Foundation of Gyeongsang National University, 2020. Special thanks to Dr. Ankit Rathi for contributing his valuable time and efforts to this work.

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