Preparation of granulated powders via freeze drying at different levels of slurry solid loading and comparison of their powder bed quality in roller-compaction-assisted binder jetting

Abstract

Granulation can improve the flowability of nanopowder and the density of resultant parts printed by binder jetting. Forward-rotating roller compaction has the potential for further improving the density. In this study, for the first time, powder recoating tests of different granulated alumina powders were conducted on a commercially available binder jetting printer equipped with a forward-rotating roller compaction system. Freeze drying was used to prepare the granulated powder. Four different granulated powders were prepared from slurries with different levels of solid loading: 2, 5, 10, and 15 vol%, respectively. Powder bed quality, including defects on powder bed surface and maximum powder bed density without defects, was compared among the granulated powders. When the compaction ratio was too high, granulated powders with low solid loading levels of 2 and 5 vol% showed much fewer compaction-induced defects (including surface ridges and edge ridges) on powder bed surface than those with high solid loading levels of 10 and 15 vol%. As the solid loading level increased from 2 to 15 vol%, the maximum powder bed density without defects decreased from 19.5% to 16.0%. This study showed that a granulated powder prepared from a low level of slurry solid loading could reduce the compaction-induced defects on powder bed surface and enhance the powder bed density in roller-compaction-assisted binder jetting.