Metal Powder Research Articles

Gas-particle-heat dynamic coupling simulation in directed energy deposition

Powder flow can affect the temperature variations in directed energy deposition (DED). However, the direct coupling mechanism remains unknown. To solve this problem, the heat and mass transfer in additive manufacturing was simulated using dynamic coupling. The interactions between the multiphase flow and heat transfer were established. A comparison with experiment shows that the accuracy of the predictions of the numerical simulation regarding powder size distributions and temperature increases is higher than 95 %. The average temperature increase of the metal powders with different weight functions was highly consistent in the simulation process. As the powder size increases, the average temperature of the powder on the printing plane decreases. This was the reason for the formation of a deeper melt pool in the case of smaller particles in the experiment. The different curvatures between the particle surface and melt pool surface lead to a decreased energy absorption efficiency in DED. The relationship between the powder features and the melt pool size was studied. A decrease in the powder flow rate increased the temperature, leading to a larger melt depth.

Analysis of the effect of flow channel structures on the centrifugal accelerated motion of particles in a vacuum state

In this study, the impact of flow channel structures on the acceleration of metal particles in a vacuum environment is explored, with the aim of enhancinge the acceleration quality in the centrifugal impact molding of metal powders. To assess this phenomenon, three evaluation indices are introduced: the average speed of particles thrown Vp\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$${V}_{p}$$\\end{document}, the average speed of the particles Vall\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$${V}_{all}$$\\end{document}, and the particle velocity distribution Vf (t). Additionally, the effects of six distinct runner structures on the centrifugal acceleration of the particles are analyzed in this research. The findings indicate that the arc-shaped flow channel structure not only ensures a more consistent acceleration process but also results in a higher ejection speed, leading to an improved acceleration effect. The unique contribution of this study is the examination of the relationship between flow channel designs and particle accelerations in a vacuum.

Study of the properties of a composite material Fe78Si9B13 / GNP in an epoxy matrix

This study investigates the properties of a composite material obtained by mixing Fe78Si9B13 metallic powders (at %) with graphene nanoplates (GNP) in an epoxy matrix. Four composite types were created with GNP weight proportions of 0%, 0.5%, 1.0%, and 1.5%. The composites were embedded in transparent epoxy with weight proportions of 10%, 15%, and 20%, and then filled into 7 x 20 mm cylindrical probes. Twelve samples were prepared, and another 12 samples were subjected to a longitudinal magnetic field of 1 kG. All samples were tested with a Universal Testing Machine (Model WDW 10E) up to a maximum force of 20 kN. The experiment recorded deformation (ΔH) vs. charge force. Most samples showed a maximum compression resistance of 390 MPa, except for a few that did not exceed 100 MPa. The magnetically oriented samples showed a greater elastic limit in the range of 200 to 270 MPa. Optical microscopy was used to observe the ordering of the particles after the application of the magnetic field. Scanning electron microscopy, energy-dispersive X-ray spectroscopy, and X-ray diffraction were used to characterize the structure of the composite components. A vibrating sample magnetometer (VSM) was used to characterize the magnetic behavior of the metallic powders in the composite.

Inter-layer structures regulated by metallic Si powders in 3D printing of silica-based ceramic cores

3D printing is an excellent choice for manufacture of ceramic cores; however, the inter-layer structures in 3D printed sample leads to anisotropy in microstructure and properties. In this paper, silica-based ceramic cores were prepared by digital light processing, and metallic Si powder was employed as mineralizer to relieve the anisotropy. The metallic Si powder converts into SiO2 in oxidation reaction with significant volume expansion, which inhibits the shrinkage rate and partly fills the interlayer gaps of the ceramic core. Meanwhile, the metal Si powder leads to lower curing thickness in 3D printing, and thicken the interlayer gaps. Due to the cooperation of the oxidation reaction and decreased curing thickness by the metallic Si powder, the 0.4 wt% of metallic Si powder reduced the anisotropy in structure and mechanical property due to the alleviated inter-layer structure and the interlayer and intralayer strengths show optimal values of 11.4 MPa and 17.2 MPa at room temperature, respectively. This work inspires new guidance to 3D printing of ceramic cores with uniform microstructure and excellent mechanical properties.

Sound Characteristics and Mechanical Properties of Metal Powder Chamber Structures Composite Materials Formed by Laser Powder Bed Fusion

Granular damping technology is a widely used method in aerospace and other industries to reduce vibration and noise. However, the technique still faces challenges such as secondary processing, additional structure, single structure, and residual stress. This article introduces a new composite material, the metal powder chamber structure (MPCS), formed through the laser powder bed fusion technology. The article explores the effects of factors like arrangement mode, volume fraction, and powder chamber diameter on the sound and mechanical properties of MPCS. The study shows that MPCS improves the sound insulation effect of the material and defies the mass law of sound insulation. The sample 4B40 using a body‐centered cubic arrangement has a sound insulation coefficient of 52 dB. The sound absorption efficiency curve presents a double peak, and the sample 6F60 exhibits the highest sound absorption efficiency of 0.76. MPCS changes the deformation stage of the material stress–strain curve, and different MPCS also alters the compression deformation mode of the composite material. By studying the effects of MPCS on sound and mechanical properties, it is hoped to provide a better and more sustainable solution for vibration and noise reduction.

Experimental impact study of ultra‑fine metal powders on technical characteristics and physical properties of foundry sodium silicate sand cores

Experimental impact study of ultra‑fine metal powders on technical characteristics and physical properties of foundry sodium silicate sand cores

Unravelling the intricacies of micro-nonuniform heating in field-assisted sintering of multiphase metallic microstructures

Micro-nonuniform heating in the field-assisted sintering (FAST) of electrically conductive powders has been a topic of discussion in the materials science community. Microstructural specifics, such as neck formation at low consolidation temperatures and density variations, have previously been ascribed to local overheating at the particle-particle contacts due to the Joule effect. However, recent theoretical modelling studies suggest that the very fast diffusion of heat within the micron-sized particles prevents the overheating, thereby challenging the conventional understanding of FAST-related heating effects. To provide a new experimental perspective on the local overheating and underscore its pivotal role in controlling the microstructure formation, we have studied the phase transformations in a Nd-Fe-B-type multiphase metallic powder during FAST. The formation of the α-Fe phase, following the peritectic decomposition of the Nd2Fe14B matrix phase expected at ≈1180 °C (TPER), was observed for FAST temperatures (TFAST) below TPER. A correlation between the electric current and the final phase composition, which can only be explained by considering the local overheating effect, was established. We showed that the formation of the α-Fe phase at TFAST <TPER can be mitigated by (i) decreasing the electric current through the sample, which is achieved by lowering the heating rate from 100 to 10 °C/min or by using electrically highly conductive pressing tools (WC) and a non-conductive coating (BN), or by (ii) interparticle necking achieved through a thermal pre-treatment of the powder compact that decreases the overall resistance. Our findings emphasize the criticality of the electric current modulation to minimize any undesired phase transformation, paving the way for future developments in rapid, FAST-based strategies aimed at refining the microstructures and tailoring the properties of multiphase metallic materials.

Powder BED Additive Manufacturing using Machine Learning Algorithms for Multidisciplinary Applications: A Review and Outlook

Abstract: Additive manufacturing overcomes the limitations associated with conventional processes, such as fabricating complex parts, material wastage, and a number of sequential operations. Powder-bed additives fall under the category of additive manufacturing process, which, in recent years, has captured the attention of researchers and scientists working in various fields of science and engineering. Production of powder bed additive manufacturing (PBAM) parts with consistent and predictable properties of powders used during the manufacturing process plays an important role in deciding printed parts' reliability in aeronautical, automobile, biomedical, and healthcare applications. In the PBAM process, the most commonly used powders are polymer, metal, and ceramic, which cannot be effectively used without understanding powder particles' physical, mechanical, and chemical properties. Several metallic powders like titanium, steel, copper, aluminum, and nickel, several polymer polyamides (nylon), polylactide, polycarbonate, glass-filled nylon, epoxy resins, etc., and the most commonly used ceramic powders like aluminum oxide (Al2O) and zirconium oxide (ZrO2) can be utilized depending upon the method being adopted during PBAM process. Adoption of some post-processing techniques for powder, such as grain refinement can also be employed to improve the physical or mechanical properties of powders used for the PBAM process. In this paper, the effect of powder parameters, such as particle size, shape, density, and reusing of powder, etc., on printed parts have been reviewed in detail using characterization techniques such as X-ray computed tomography, scanning electron microscopy, and X-ray photoelectron spectroscopy. This helps to understand the effect of particle size, shape, density, virgin and reused powders, etc., used during the PBAM process. This article has reviewed the selection of appropriate process parameters like laser power, scanning speed, hatch spacing, and layer thickness and their effects on various mechanical or physical properties, such as tensile strength, hardness, and the effect of porosity, along with the microstructure evolution. One of the drawbacks of additive manufacturing is the variability in the quality of printed parts, which can be eliminated by monitoring the process using machine learning techniques. Also, the prediction of the best combination of process parameters using some advanced machine learning algorithms (MLA), like random forest, k nearest neighbors, and support vector machine, can be effectively utilized to quantify the performance parameters in the PBAM process. Thus, implementing machine learning in the additive manufacturing process not only helps to learn the fundamentals but helps to identify, predict and help to make actionable recommendations that help optimize printed parts quality. The performance of various MLAs has been evaluated and compared for projecting future research directions and suggestions. In the last part of this article, multidisciplinary applications of the PBAM process have been reviewed in detail. Additive manufacturing processes carried out by using conventional machines, called hybrid additive manufacturing, have also been reviewed by discussing their methods and arrangements in detail.

High-resolution metal 3D printing via digital light processing

Three-dimensional (3D) printing of complex metallic parts with a micrometer resolution can extend the application of additive manufacturing to various fields wherein the mechanical, thermal, and electrical properties of metals are essential. Digital light processing (DLP) offers high-resolution and scalable 3D printing via vat photopolymerization (VPP). We present a high-precision metal 3D printing method, namely lithography metal additive manufacturing (LMAM) that uses DLP for a photosensitive resin filled with metal powder. The printing process and sintering conditions for a stainless-steel feedstock are discussed. Highly complex and hollow structures with a spatial resolution of 35 μm and surface roughness as low as 1 <Ra < 2 μm can be printed on a decimeter scale without any support structures. The density and tensile strength of the sintered parts are 99.3 % and 93 %, respectively, of those of annealed 316 L steel. The LMAM method is suitable for manufacturing small and highly accurate devices with tailored designs in diverse areas, such as microheat exchangers, biomedical implants, and metamaterials, as well as extends metal 3D printing to chemical engineering for pharmaceutical applications.

Synthesis of nanocrystalline zinc powder: Investigating the influence of crystallite size and lattice strain on Debye-Waller factors

In this investigation, nano-sized zinc particles were synthesized through a ball milling process. The Zn metal powder, milled for durations ranging from 0 to 150 h, underwent analysis using X-ray diffraction (XRD). The study focused on determining PS (particle size) and assessing the influence of LS (lattice strain) on the DWFs (Debye–Waller factors), employing XRD principles. LSs were induced in zinc through varying milling durations, and X-ray diffractograms were captured at different stages of the milling process. The results revealed a reduction in PS and an increase in LS with prolonged milling, reaching a predominantly amorphous state at 150 h. By establishing the correlation between strain and effective DWF, the study estimated DWFs for zero strain in zinc.

Effect of laser focal point position on porosity and melt pool geometry in laser powder bed fusion additive manufacturing

In laser powder bed fusion (PBF-LB) additive manufacturing (AM), the laser beam is the fundamental tool used to selectively melt metal powder layer-upon-layer to form a 3-dimensional part. Studies on the effect of the laser scanning parameters (power, speed, hatch distance, and scanning strategy in general) on part quality are abundant; however, far less emphasis has been given to the effect of the laser beam and how it is focused on the laser-material interaction plane. Here, we have studied the effect of laser beam focal point position on porosity and melt pool geometry in PBF-LB AM. In addition, we also study how the various energy density parameters developed for laser melting processes correlate with melt pool dimensions in a situation where the laser beam focal point position (and the beam diameter and laser intensity change at work plane caused by it), is taken into consideration. Furthermore, we assess the possibility of using co-axial, photodiode-based melt pool monitoring signals as a means to monitor the thermal emissions of the process, and how it correlates with the resulting melt pool geometry. It was found that melt pool penetration experiences a major decrease when the focal point position is shifted by more than ±1 mm (or 30% of Rayleigh length), which could be considered as a tolerance limit for acceptable focus shift in PBF-LB machines. Focus shifts larger than this were effectively captured by the photodiode signals, indicating the potential of using such photodiode-based melt pool monitoring systems for continuous monitoring of focus shift in PBF-LB AM. Finally, it was shown that all the studied energy density parameters, except volumetric energy density, were able to capture the trend in normalized melt pool dimensions when focus position is introduced as a variable. A new energy density metric by normalizing the melt pool monitoring signal intensity with the beam area was introduced and shown to correlate with the normalized melt pool dimensions.

Effect of laser etching on surface characteristics and porcelain bond to soft milled and direct metal laser sintered cobalt chromium alloys

Statement of problemThe surface topography of metal substrate can affect its bond to porcelain. A neodynium-doped yttrium aluminum garnet (Nd:YAG) laser has been introduced to modify the metal surface topography and improve porcelain bond strength. However, studies on the effect of laser etching on metal to porcelain bond strength are lacking. PurposeThe purpose of this in vitro study was to determine the effect of Nd:YAG laser etching on the surface roughness and wettability of and the porcelain bond strength to cobalt chromium (Co-Cr) substrate fabricated by milling and direct metal laser sintering (DMLS). Material and methodsThirty-two 0.5×3×25-mm Co-Cr specimens were fabricated by milling soft Co-Cr (M group) and DMLS Co-Cr metal powder (DML group). The surface topography of representative specimens from each study group was assessed under a scanning electron microscope (SEM) and an atomic force microscope (AFM). All specimens were assessed for surface roughness using a contact profilometer, and for wettability with a contact angle goniometer. Half of the specimens of each study group (n=8) were subjected to surface laser etching by using a Nd:YAG laser. The specimens subjected to etching were assessed again for surface topography and wettability. All specimens in both study groups were veneered with porcelain. The porcelain bond strength was tested with a 3-point bend test in a universal testing machine. The results were statistically analyzed with 2-way ANOVA test followed by the post hoc Tukey test for pairwise comparisons (α=.05). ResultsAfter etching, the M group had a higher mean ±standard deviation Ra and Rz of 2.9 ±0.6 and 17.7 ±3.2 µm and significantly better wettability and bond strength of 79 ±6 and 52 ±13 MPa. In contrast, after etching, the DMLS group had a significantly lower Ra and Rz of 7.9 ±2.4 and 41.8 ±9.3 µm and significantly lower wettability and bond strength of 87 ±4 and 70 ±10 MPa. The DMLS group had a significantly higher roughness and bond strength than the M group before and after laser etching. The SEM and AFM showed different surface topography in the study groups. ConclusionsThe manufacturing process of Co-Cr substrate had a significant effect on surface characteristics and porcelain bond strength. Laser etching improved the surface topography and bond strength of milled Co-Cr but not of DMLS Co-Cr.

Comparative Study of the Life Prediction and Failure Analysis of Metal Powder (Vanadium-V) Coated on Crankshaft

The crankshaft plays a crucial role in the efficient operation of internal combustion engines, converting piston reciprocating motion into rotary motion. This study aims at the life prediction and failure analysis of metal powder (Vanadium-V) coated on crankshaft using numerical method. It was modelled with SOLIDWORDS version 2019 and imported to ANSYS 2020 RI environment for static structural analysis. Numerical results of total deformations obtained from ANSYS are shown with the minimum value and maximum for propose material 7.3172e-5 and 0.00065855 respectively, and for the existing material value having 0.00014795 and 0.0013316 as well. Maximum and minimum values are 0.018841 and 2.9158e-7 in crankshaft equivalent elastic strain distributions in the existing material respectively. Results also show that maximum equivalent elastic strain is observed in propose with 0.097538 and minimum 3.1017e-7. The maximum value is 1.3933e9 and minimum value is 26418 of the stress found around the crankshaft of the propose and is stretched where there is concentration of pressure. The maximum stress intensity is observed in existing material with 1.5139e9 with minimum value of 30833. Results reveal significant improvements in total deformations, elastic strain distributions, and stress values for the proposed vanadium-coated material compared to the existing one. Despite a mere 0.0003mm thickness, the vanadium coating offers cost-effectiveness, better performance with cheaper lubricants, reduced friction, and enhanced dimensional tolerance at higher pressures. Results therefore proposed vanadium incorporated to inhibit grain growth to enhance strength and toughness of hardened steel.

Evaluation of the Corrosion Resistance of Watch Links from 316L and 904L Austenitic Stainless Steels Obtained by the Metal Injection Molding (MIM) Technique Intended to Be in Contact with Human Skin

Watchmaking manufacturers obtain their bracelet links from machining drawn metal profiles. But, today, there is another process that represents an alternative to manufacture them: metal injection molding using metal powders (MIM technology). This process is less expensive than the machining of drawn metal profiles. The aim of this study was to evaluate the corrosion behavior and the nickel cation release of two stainless steel alloys: 316L MIM and 904L MIM. The general corrosion behavior was evaluated by the rotating electrode technique; the galvanic corrosion measurements were conducted with a 316L AISI bulk coupling partner. The pitting corrosion behavior was evaluated in FeCl3 0.5 M media (according to ASTM G48-11). For comparison, a complementary study was conducted on 316L and 904L bulk alloys. The Ni cation release tests were conducted on 316L and 904L MIM and bulk samples according to EN 1811. Different electrochemical parameters were measured and calculated (open circuit potential, polarization resistance, corrosion current and Tafel slopes, coulometric analysis). Generally, if MIM steels are compared with conventional steels, their corrosion resistance behavior is inferior. In the couplings studied, the galvanic currents generated are very important. The shape of the curves also reveals the presence of localized corrosion phenomena. According to tests in ferric chloride, MIM steels were noted to have inferior behavior compared to conventional steels. MIM type 904L steels are comparable in behavior to conventional type 316L steels. The quantities of nickel released according to EN 1811 were very significant (2 mg cm−2 week−1 up to 24 mg cm−2 week−1) and did not meet the requirements of the European directive (0.5 µg cm−2 week−1). In conclusion, conventional steels studied under the same experimental conditions revealed a better behavior compared to MIM steels independently of the phenomenological parameters chosen.

3D printing of low carbon steel using novel slurry feedstock formulation via material extrusion method

Conventional 3D metal printing methods, such as laser sintering and binder jetting are often associated with high initial capital costs that make them inaccessible to many consumers. In this article, an economical alternative approach to 3D metal printing is presented, which uses a slurry-based formulation with the material extrusion method. This method involves a novel slurry feedstock of metal powder and liquid binder, which can be printed at room temperature to form green samples without the need for equipment such as a laser source, binder jetting head, or heated nozzle. It is followed by a thermal treatment process to fuse the printed samples into a metal article. The slurry is prepared by blending carbon steel powder with a cellulose derivative binder and additives. Rheological behaviours of different metal contents and binder concentrations are being investigated to determine the optimum printable slurry formulation. It is found that the optimum slurry feedstock formulation comprises 45 vol% metal content, 54 vol% cellulose derivative binder solution at a concentration of 300 g/L, and 1 vol% defoamer. The resulting slurry has fast-drying shear-thinning behaviour and a high storage modulus of 4 × 107 Pa to sustain the printed article at room temperature. The printed articles exhibited an average linear shrinkage of 12.36%, with less than a 1% linear shrinkage difference between X, Y, and Z directions after thermal treatment. The measured densities of the sintered articles were 95% ± 2% compared to the ASTM B783 (material code F-0000). The sintered articles have a measured carbon content of 0.28 ± 0.02%, hardness of 64.15 ± 9 HV, ultimate tensile strength of 255.33 MPa and Young's modulus of 130.47 GPa. This work demonstrates the viability of this additive manufacturing method in producing metal parts with comparable properties to conventional manufacturing.

Investigation and Optimization on Parameters of Gas Additive Powder Mixed Near Dry –EDM (GAPMNDEDM) by using Taguchi based- Grey Relational Optimization

The Gas Additive Powder Mix near Dry Electric Discharge Machining (GAPMND-EDM) serves a manufacturing purpose, specifically for cutting hard materials. This involves the removal of material from a workpiece via fusion, ablation, and evaporation caused by the heat energy generated through electric sparks during energy supply. The process offers several advantages in terms of performance and characteristics. This research project aims to optimize key process parameters, including material removal rate, surface roughness, residual stresses, and microhardness. The study employs a methodology that combines the standard deviation-based objective weighting method with GRA (Gray Relational Analysis) optimization to enhance the hybrid GAPMND-EDM process when applied to EN-31 material. Experimental runs were conducted to evaluate the impact of various input factors, such as pulse-on time, discharge current, dielectric fluid pressure, and metallic powder concentration. The taguchi-based GRA method was utilized for this purpose, and the experimental design followed an L-27 orthogonal array with the assistance of Minitab-19 software. A total of 27 experiments were performed, encompassing diverse combinations of process parameters. Subsequently, an ANOVA (Analysis of Variance) was executed to analyze the influence of pulse-on time, discharge current, dielectric fluid pressure, and metallic powder concentration on Material Removal Rate (MRR), Surface Roughness (SR), Residual Stress (RS), and Microhardness (MH). The result shows the optimal combination of parameters, denoted as A2B2C2D1, was identified as the preferred configuration.

Precise control of atomization initial stage to address nozzle clogging issue in the vacuum induction-melting gas atomization process

Vacuum induction-melting gas atomization (VIGA) is considered a widely applied method to prepare metal powders. However, the nozzle clogging problem in the VIGA process seriously affects the continuity of production and greatly increases the economic and time costs. In the atomization initial stage, the existence of unsteady state atomization mainly results in the nozzle clogging challenge. To understand the formation mechanism of nozzle clogging, a computational fluid dynamics (CFD) model was established to simulate the influence of unsteady state atomization sequence on the primary atomization of alloy melt. Typically, there are two kinds of sequence including starting the gas before pooling the alloy (namely, GA) and pouring the alloy before opening the gas (AG). The movement trajectory of the alloy melt droplet at the end of the delivery-tube was clarified. Based on CFD simulation, the atomization sequence of AG and GA was precisely controlled in the atomization pressure range of 2.5 MPa, 3.5 MPa, and 4.5 MPa to address the nozzle clogging issue. In the GA process, relatively finer powder was obtained at 3.5 MPa without nozzle clogging occurring. In contrast, the AG process greatly reduces the probability of nozzle clogging at 2.5–4.5 MPa, the final prepared powder is coarser. The predicted results of industrial experiments and numerical simulations are consistent. This study provides theoretical support for understanding the formation mechanism of nozzle clogging during the VIGA process.

Non-heat source forming technology of binder jetting metal powder and its post-treatment process

Non-heat source forming technology of binder jetting metal powder and its post-treatment process

Thermodynamic Investigations for Combustion-Assisted Synthesis of Lithium Orthosilicate Powders

The study investigates the combustion-assisted synthesis of lithium orthosilicate (Li4SiO4) powders for potential CO2 capture applications. Technical-grade lithium carbonate and metallic silicon powders were used as starting materials. Synthesis conditions were explored across temperatures ranging from 500 to 900 °C and different holding durations. Thermodynamic modeling using FactSage 8.2 software suggested that Li4SiO4 production is feasible at temperatures of 700 °C and higher with metallic silicon as the silicon source, which was confirmed experimentally. Characterization of the synthesized powders involved X-ray diffraction, specific surface area determination, particle size distribution analysis, scanning electron microscopy, and CO2 uptake tests. Despite having the lowest Li4SiO4 content as 83.7%, the sample synthesized at 700 °C with 45 min of holding time showed the best CO2 uptake performance as 12.80 wt% while having the lowest crystallite size value (126.58 nm), the highest specific surface area value (4.975 m2/g) and the lowest average particle size value (10.85 µm) which are highly effective on the CO2 uptake performance of such solid sorbents. The study concludes that while challenges remain in achieving optimal CO2 capture performance, it lays a foundation for utilizing lithium orthosilicate in carbon capture applications.Graphical

Extrusion-based additive manufacturing of aluminium-filled ethylene vinyl acetate for electrically conductive 3D part printing

Addition of carbon-based fillers to enhance electrical conductivity is quite popular but addition of metal fillers is still a challenge due to oxidation and unavailability of metal nano-powders. In this paper, fabrication of flexible electrically conductive parts is proposed using aluminium metal powder as filler material. Aluminium metal powder is mixed with ethylene vinyl acetate (EVA) by chemical mixing process. Cyclohexane is used as a mixing medium in which EVA is dissolved and aluminium powder is added by weight. An in-house developed material extrusion tool mounted on CNC milling machine is used for printing of flexible electrically conductive samples. Pellet-based extrusion process is used for printing flexible parts as conventional filament-based 3D is not suitable due to buckling. Composite with filler loading in 5%, 10%, 20% and 30% were made and samples were printed. Investigations were made on printability of composite and its electrical conductivity. The aluminium fillers presence and dispersion in polymer were ensured. The samples were printed in temperature range of 130–140 °C through 0.4 mm diameter nozzle. It was found that the resistivity drops by around 60% on varying the filler concentration from 20% to 30%; 81.6 kΩ is the lowest resistance observed with 30% filler concentration. A simulation study on thermal behaviour of material extrusion tool has been done and is validated practically. The application of flexible electrically conductive parts lies in fabrication of various electronic devices like antenna, display boards, solar panels, and wearable health monitoring devices.