MATERIALS OF Additive Manufacturing TECHNOLOGY (1).pptx

What are the different materials used in additive manufacturing

1. MATERIALS OF AM TECHNOLOGY ASSIGNMENT

2. INTRODUCTION POLYMERS CERAMICS WAX METALS CONTENT

3. INTRODUCTION Materials requirements for AM include: ability to produce the feedstock in a form amenable to the specific AM process. suitable processing of the material by AM. capability to be acceptably post- processed to enhance geometry and properties. Feedstock material can be of solid, liquid and powder type. Generally, polymers, metals, and composites are considered.

4. Polymers Various thermoplastic polymers have been used in 3D printing for decades. Filaments known by their acronyms (like ABS, PLA and PVA) are integral to the production of a wide variety of parts servicing numerous industries. Potential AM applications using thermoplastics are expanding as researchers discover ways to strengthen objects along the Z axis.

5. Acrylonitrile butadiene Styrene(ABS) ABS is a strong and durable material with excellent dimensional accuracy. To a create a 3D printed object using ABS the filament must be heated to a relatively high 230-250 degree C. The higher melting point of ABS makes for objects that are relatively wrap and crack resistant.

6. Acrylonitrile butadiene Styrene(ABS)

7. Polylactide (PLA) Polylactide or polylactic acid (PLA) filaments comprise one of the most popular categories of thermoplastic materials. Since PLA is made from cornstarch and sugar cane, it is biodegradable and therefore eco friendly. Due to its sugar content , PLA filament gives off a slightly sweet odor when heated.

8. Nylon Nylon is strong, flexible and durable. It also demonstrate excellent material memory. Objects printed from Nylon filament demonstrate good adhesion between layers. Since Nylon is moisture sensitive, it is often necessary to print in a vacuum or at high temperatures.

9. Polycarbonate (PC) PC plastics are as much as 10 times more impact resistant than certain acrylics. Although pc is naturally transparent, is possible to color PC materials as desired. Polyvinyl Alcohol(PVA) PVA is a water soluble compound used to print support structures in internal cavities and beneath overhangs. Therefore, PVA enables the creation of complex objects in dual extrusion printers when PLA is the primary material.

10. Ceramics and Glass Ceramics: AM using silicon carbide( SiC ) ceramics offers short run, cost effective production, in part because the time consuming process of creating molds is eliminated. Geometrically complex ceramic parts deliver better performance with less weight, properties very attractive to jet engine and rocket engine manufacturers. Commercially viable production is already underway using various AM processes, including binder jetting, material extrusion and stereolithography.

11. The process yields ceramic parts with injection mold quality, but with more intricate designs, including delicate cavities and undercuts. The tool free production method eliminates unmolding and other inefficient that can reduce your costs. In general ceramic 3D printing is quickly progressive from the short run production of specialized components to the mass production of customized products. CERAMICS

12. In SLS glass powder is partially melted by lasers to create 3D objects useful in architectural and product design. There may also be applications for 3D- printed glass in the field of optoelectronics. Due to its thermal stability and high transmissivity, fused quartz is also being considered for optical, communication, electronic and hermetic sealing applications . GLASS

13. Research continues into the feasibility of efficiently producing optically transparent glass using a material extrusion process. The resulting stream of molten glass looks like honey. If the production of optically transparent glass using additive manufacturing is perfected, completely new applications may appear.

14. Wax In the Additive Manufacturing industry, wax 3D printing is made with multi jet printers. Molten wax filament is deposited by nozzles on an aluminum build platform that moves down, layer by layer. This whole printing process can print products with an incredibly high resolution of 25 μm. Allows to create pieces with a virtually unlimited level of detail. Wax used for Additive Manufacturing is made of 100% pure castable wax but can have various colours and properties.

15. Metals Powder bed fusion and directed energy deposition are the main AM processes that are commercially used to manufacture quality metal parts. Binder jetting is also used to produce metal parts. The usage of various metals as a feedstock is limited accordingly: For powdered feedstock, particles should preferably be spherical with a certain size distribution. For DED, must be weldable and castable to be successfully processed in AM. This list includes stainless steel, nickel-based alloys, titanium alloys and aluminium alloys.

16. Typical particle sizes for PBF-L are in the range of 10–60 μm and 60–105 μm for PBF-EB. Wire diameters 0.8mm - 1.4mm. As a benefit, wire feedstock has significantly less surface area per kilogram than powder product and is less likely to oxidize and absorb moisture or contaminants. Wire forms are easier to store and handle compared to metal powders.

17. Material related challenges Affinity for atmosphere Powder particles of Al and Al alloys have a stable Al2O3 layer at their surface. Stable oxides hamper the melt coalescence. Repelling of powder particles due to the negative charge induced by the electron beam. Leading to particle ejection from the powder bed. Although, addition of a new layer will break these oxides. Some particles can stay behind in the solidified microstructure. Brittle particles increase stresses and detrimental to mechanical properties.

18. Material related challenges When using certain materials, like titanium, shielding is necessary to create an inert atmosphere to ensure the right building conditions. However, the inert gas chamber limits the size of parts. Installing such a chamber will increase the cost of the equipment.

19. Material related challenges Residual stress Generally, AM residual stress distributions feature high tensile stresses at outer surfaces, balanced by a large zone of compressive stresses in the center. While deformations due to residual stresses are a general phenomenon, the occurrence of cracks and the type of cracks are material dependent. For example, Ti6Al4 V (that is less prone to cracking) and M2 high speed steel (that is more prone to cracking) develop macroscopic cracks. Nickel based alloys with a high Al and Ti content based alloys exhibit microcracking .

20. Common additive manufacturing alloys and applications

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