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Spoerk, M.
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article
Additive Manufacturing of Steel and Copper Using Fused Layer Modelling
Abstract
FusedLayerModelling(FLM)isoneoutofseveralmaterialextrusion(ME)additivemanufacturing(AM)methods.FLMusuallydealswithprocessing of polymeric materials but can also be used to process metal-filledpolymericsystemstoproducemetallicparts.UsingFLMforthispurposehelpstosavecostssincetheFLMhardwareischeapcomparedtoe.g.directmetallaserprocessinghardware,andFLMoffersanalternative route to the production of metallic components. ToproducemetallicpartsbyFLM,themethodologyisdifferentfromdirectmetalprocessingtechnologies,andseveralprocessingstepsarerequired:First,filamentsconsistingofaspecialpolymer-metalcompositionareproduced.ThefilamentisthentransformedintoshapedpartsbyusingFLMprocesstechnology.Subsequentlythepolymericbinder is removed (”debinding”) and finally the metallic powder body is sintered.Dependingonthemetalpowderused,thebindercomposition,theFLMproductionparametersandalsothedebindingandsinteringprocesses must be carefully adapted and optimized.The focal points of this study are as following: 1.ToconfirmthatmetallicpartscanbeproducedbyusingFLMplusdebindingandsinteringasanalternativeroutetodirectmetaladditivemanufacturing.2.Determinationofprocessparameters,dependingontheusedmetalpowders (steel and copper) and optimization of each process step.3.Comparisonoftheproductionpathsforthedifferentmetalpowdersand their debinding and sintering behavior as well as the final properties of the produced parts.The results showed that both materials were printable after adjusting the FLMparameters,metallicpartsbeingproducedforbothmetalpowdersystems.Theproductionmethodandthesinteringprocessworkedoutwellforbothpowders.Howevertherearespecificchallengesinthesintering process that have to be overcome to produce high quality metal parts. This study serves as a fundamental basis for understanding when it comestotheprocessingofsteelandcopperpowderintometallicpartsusing FLM processing technology.