Open Access

Georg Pöhle, Peter Quadbeck, Sebastian Riecker, Christian Kukla, Vahid Momeni, Stephan Schuschnigg

• Fused Filament Fabrication (FFF) is a widespread additive manufacturing technology, mostly in the field of printable polymers. The use of filaments filled with metal particles for the manufacture of metallic parts by FFF presents specific challenges regarding debinding and sintering. For aluminium and its alloys, the sintering temperature range overlaps with the temperature range of thermalFused Filament Fabrication (FFF) is a widespread additive manufacturing technology, mostly in the field of printable polymers. The use of filaments filled with metal particles for the manufacture of metallic parts by FFF presents specific challenges regarding debinding and sintering. For aluminium and its alloys, the sintering temperature range overlaps with the temperature range of thermal decomposition of many commonly used “backbone” polymers, which provide stability to the green parts. Moreover, the high oxygen affinity of aluminium necessitates the use of special sintering regimes and alloying strategies. Therefore, it is challenging to achieve both low porosity and low levels of oxygen and carbon impurities at the same time. Feedstocks compatible with the special requirements of aluminium alloys were developed. We present results on the investigation of debinding/sintering regimes by Fourier Transform Infrared spectroscopy (FTIR) based In-Situ Process Gas Analysis and discuss optimized thermal treatment strategies for Al-based FFF.…