Adhesive and alloying properties of dual purpose polyfurfuryl alcohol binder for binder jet additive manufacturing of steel
In-situ alloying in steel can be achieved in the binder jet additive manufacturing process by incorporating alloying elements into the binder. However, using binders with nanoparticle suspensions often leads to challenges with particle dispersion uniformity and nozzle clogging. To circumvent these l...
| Main Authors: | , , , , , , , |
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| Other Authors: | |
| Format: | Journal Article |
| Language: | English |
| Published: |
2024
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| Online Access: | https://hdl.handle.net/10356/178935 |
| _version_ | 1826126580791902208 |
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| author | Tan, Wei Xin Chiang, Po-Ju Tan, Li Ping Ramanujan, Raju V. Tan, Ming Jen Ong, Adrian Jangam, John Samuel Dilip Lai, Chang Quan |
| author2 | School of Materials Science and Engineering |
| author_facet | School of Materials Science and Engineering Tan, Wei Xin Chiang, Po-Ju Tan, Li Ping Ramanujan, Raju V. Tan, Ming Jen Ong, Adrian Jangam, John Samuel Dilip Lai, Chang Quan |
| author_sort | Tan, Wei Xin |
| collection | NTU |
| description | In-situ alloying in steel can be achieved in the binder jet additive manufacturing process by incorporating alloying elements into the binder. However, using binders with nanoparticle suspensions often leads to challenges with particle dispersion uniformity and nozzle clogging. To circumvent these limitations, we investigated the feasibility of using a particle-free binder based on poly(furfuryl alcohol) (PFA) for binder jet 3D printing of steel. The PFA binder serves dual purposes – (i) imparting structural integrity to the as-printed green part and (ii) providing carbon upon pyrolysis to alloy the printed iron parts into steel. The PFA binder was first dispensed layer-by-layer into a low alloy steel powder bed to produce green parts with a storage modulus of 3360 MPa and a compressive strength of up to 9 MPa. Compared to the control, a commercial carbon binder ink, the present particle-free PFA formulation offered better green part rigidity (+18 %) and strength (+18.5 %) for the same amount of carbon alloying. The green parts were then subjected to debinding and sintering to consolidate the steel powder particles. During vacuum sintering, the PFA was pyrolyzed and left behind a carbon residue which diffused into the steel part to form a hard and strong ferrite-carbide aggregate phase that significantly enhanced the hardness, yield strength and ultimate tensile strength of the sintered steel parts. Furthermore, by varying the amount of this particle-free binder formulation at different locations, components with site-specific microstructures and mechanical responses, confirmed through hardness tests and digital image correlation, were also demonstrated. |
| first_indexed | 2024-10-01T06:54:58Z |
| format | Journal Article |
| id | ntu-10356/178935 |
| institution | Nanyang Technological University |
| language | English |
| last_indexed | 2024-10-01T06:54:58Z |
| publishDate | 2024 |
| record_format | dspace |
| spelling | ntu-10356/1789352024-07-12T15:44:40Z Adhesive and alloying properties of dual purpose polyfurfuryl alcohol binder for binder jet additive manufacturing of steel Tan, Wei Xin Chiang, Po-Ju Tan, Li Ping Ramanujan, Raju V. Tan, Ming Jen Ong, Adrian Jangam, John Samuel Dilip Lai, Chang Quan School of Materials Science and Engineering School of Mechanical and Aerospace Engineering HP-NTU Digital Manufacturing Corporate Lab Engineering Additive manufacturing Pyrolysis In-situ alloying in steel can be achieved in the binder jet additive manufacturing process by incorporating alloying elements into the binder. However, using binders with nanoparticle suspensions often leads to challenges with particle dispersion uniformity and nozzle clogging. To circumvent these limitations, we investigated the feasibility of using a particle-free binder based on poly(furfuryl alcohol) (PFA) for binder jet 3D printing of steel. The PFA binder serves dual purposes – (i) imparting structural integrity to the as-printed green part and (ii) providing carbon upon pyrolysis to alloy the printed iron parts into steel. The PFA binder was first dispensed layer-by-layer into a low alloy steel powder bed to produce green parts with a storage modulus of 3360 MPa and a compressive strength of up to 9 MPa. Compared to the control, a commercial carbon binder ink, the present particle-free PFA formulation offered better green part rigidity (+18 %) and strength (+18.5 %) for the same amount of carbon alloying. The green parts were then subjected to debinding and sintering to consolidate the steel powder particles. During vacuum sintering, the PFA was pyrolyzed and left behind a carbon residue which diffused into the steel part to form a hard and strong ferrite-carbide aggregate phase that significantly enhanced the hardness, yield strength and ultimate tensile strength of the sintered steel parts. Furthermore, by varying the amount of this particle-free binder formulation at different locations, components with site-specific microstructures and mechanical responses, confirmed through hardness tests and digital image correlation, were also demonstrated. Agency for Science, Technology and Research (A*STAR) Submitted/Accepted version This work was supported by the IAF-ICP grant (I1801E0028) and the AME Programmatic Fund by the Agency for Science, Technology and Research, Singapore under Grant No. A1898b0043. 2024-07-10T07:22:56Z 2024-07-10T07:22:56Z 2024 Journal Article Tan, W. X., Chiang, P., Tan, L. P., Ramanujan, R. V., Tan, M. J., Ong, A., Jangam, J. S. D. & Lai, C. Q. (2024). Adhesive and alloying properties of dual purpose polyfurfuryl alcohol binder for binder jet additive manufacturing of steel. Additive Manufacturing, 86, 104212-. https://dx.doi.org/10.1016/j.addma.2024.104212 2214-7810 https://hdl.handle.net/10356/178935 10.1016/j.addma.2024.104212 2-s2.0-85193636135 86 104212 en I1801E0028 A1898b0043 Additive Manufacturing © 2024 Elsevier B.V. All rights are reserved. This article may be downloaded for personal use only. Any other use requires prior permission of the copyright holder. The Version of Record is available online at: http://dx.doi.org/10.1016/j.addma.2024.104212 application/pdf |
| spellingShingle | Engineering Additive manufacturing Pyrolysis Tan, Wei Xin Chiang, Po-Ju Tan, Li Ping Ramanujan, Raju V. Tan, Ming Jen Ong, Adrian Jangam, John Samuel Dilip Lai, Chang Quan Adhesive and alloying properties of dual purpose polyfurfuryl alcohol binder for binder jet additive manufacturing of steel |
| title | Adhesive and alloying properties of dual purpose polyfurfuryl alcohol binder for binder jet additive manufacturing of steel |
| title_full | Adhesive and alloying properties of dual purpose polyfurfuryl alcohol binder for binder jet additive manufacturing of steel |
| title_fullStr | Adhesive and alloying properties of dual purpose polyfurfuryl alcohol binder for binder jet additive manufacturing of steel |
| title_full_unstemmed | Adhesive and alloying properties of dual purpose polyfurfuryl alcohol binder for binder jet additive manufacturing of steel |
| title_short | Adhesive and alloying properties of dual purpose polyfurfuryl alcohol binder for binder jet additive manufacturing of steel |
| title_sort | adhesive and alloying properties of dual purpose polyfurfuryl alcohol binder for binder jet additive manufacturing of steel |
| topic | Engineering Additive manufacturing Pyrolysis |
| url | https://hdl.handle.net/10356/178935 |
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