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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 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.
Gas Analysis and Optimization of Debinding and Sintering Processes for Metallic Binder-Based AM*
(2022)
Binder-based additive manufacturing processes for metallic
AM components in a wide range of applications usually use
organic binders and process-related additives that must be
thermally removed before sintering. Debinding processes are
typically parameterized empirically and thus far from the optimum.
Since debinding based on thermal decomposition processes
of organic components and the subsequent thermochemical
reactions between process atmosphere and metal
powder materials make uncomplicated parameterization difficult,
in-situ instrumentation was introduced at Fraunhofer
IFAM. This measurement method relies on infrared spectroscopy
and mass spectrometry in various furnace concepts to
understand the gas processes of decomposition of organic
components and the subsequent thermochemical reactions
between the carrier gas atmosphere and the metal part, as well
as their kinetics. This method enables an efficient optimization
of the temperature-time profiles and the required atmosphere
composition to realize dense AM components with low contamination.
In the paper, the optimization strategy is presented,
and the achievable properties are illustrated using a fused
filament fabrication (FFF) component example made of 316L
stainless steel.