Additive manufacturing of carbon steel with site-specific compositions and properties using binder jetting and spark plasma sintering

The rational variation of properties with location in a unitized component can confer highly desirable traits such as site-specific mechanical properties. To achieve voxel level control throughout the 3D printed part, we employed binder jet 3D printing to deposit carbon in selected regions of each l...

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Main Authors: Chiang, Po-Ju, Sun, Li, Tan, Li Ping, Singham, Jonathan, Zhao, Yida, Hu, Huanlong, Aik, Khor Khiam, Ramanujan, Raju V., Jangam, John Samuel Dilip, Lai, Chang Quan
Other Authors: School of Mechanical and Aerospace Engineering
Format: Article
Language:English
Published: 2024
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Online Access:https://hdl.handle.net/10356/174652
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Institution: Nanyang Technological University
Language: English
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spelling sg-ntu-dr.10356-1746522024-04-13T16:48:56Z Additive manufacturing of carbon steel with site-specific compositions and properties using binder jetting and spark plasma sintering Chiang, Po-Ju Sun, Li Tan, Li Ping Singham, Jonathan Zhao, Yida Hu, Huanlong Aik, Khor Khiam Ramanujan, Raju V. Jangam, John Samuel Dilip Lai, Chang Quan School of Mechanical and Aerospace Engineering School of Materials Science and Engineering HP-NTU Digital Manufacturing Corporate Lab Engineering Additive manufacturing Mechanical properties The rational variation of properties with location in a unitized component can confer highly desirable traits such as site-specific mechanical properties. To achieve voxel level control throughout the 3D printed part, we employed binder jet 3D printing to deposit carbon in selected regions of each layer of the steel powder bed. The printed green part was then de-binded and densified using Spark Plasma Sintering (SPS). With the use of SPS process, the sintering time was reduced dramatically, restricting the diffusion of carbon in steel and allowing a sharp change in carbon concentration over strips as narrow as ∼ 0.5 mm. Our results show that the porosity was reduced from ∼ 10% to ∼ 1% and the grain sizes from ∼ 100 µm to ∼ 10 µm, when compared to conventionally sintered parts, which in turn improved the yield strength (up to 3.2×), ultimate tensile strength (up to 2.5×) and ductility of the samples (up to 1.9×). Isostrain (Voight composite) and isostress (Reuss composite) samples, composed of high carbon steel and low carbon steel materials, exhibited modulus and strength values in between those of the constituents. However, the ductility and toughness of the site-specific patterned parts were lower than either high carbon or low carbon steel for the selected design parameters, which is in good agreement with predictions from analytical modelling and finite element simulations. This result indicates that the ductility and toughness of a composite are not mathematically bounded by that of its constituent materials, unlike modulus, density and strength. 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 Nos. A1898b0043 and A18B1b0061. 2024-04-07T01:43:48Z 2024-04-07T01:43:48Z 2024 Journal Article Chiang, P., Sun, L., Tan, L. P., Singham, J., Zhao, Y., Hu, H., Aik, K. K., Ramanujan, R. V., Jangam, J. S. D. & Lai, C. Q. (2024). Additive manufacturing of carbon steel with site-specific compositions and properties using binder jetting and spark plasma sintering. Additive Manufacturing, 82, 104034-. https://dx.doi.org/10.1016/j.addma.2024.104034 2214-7810 https://hdl.handle.net/10356/174652 10.1016/j.addma.2024.104034 2-s2.0-85185402771 82 104034 en A1898b0043 A18B1b0061 Additive Manufacturing © 2024 Elsevier B.V. All rights 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://doi.org/10.1016/j.addma.2024.104034. application/pdf
institution Nanyang Technological University
building NTU Library
continent Asia
country Singapore
Singapore
content_provider NTU Library
collection DR-NTU
language English
topic Engineering
Additive manufacturing
Mechanical properties
spellingShingle Engineering
Additive manufacturing
Mechanical properties
Chiang, Po-Ju
Sun, Li
Tan, Li Ping
Singham, Jonathan
Zhao, Yida
Hu, Huanlong
Aik, Khor Khiam
Ramanujan, Raju V.
Jangam, John Samuel Dilip
Lai, Chang Quan
Additive manufacturing of carbon steel with site-specific compositions and properties using binder jetting and spark plasma sintering
description The rational variation of properties with location in a unitized component can confer highly desirable traits such as site-specific mechanical properties. To achieve voxel level control throughout the 3D printed part, we employed binder jet 3D printing to deposit carbon in selected regions of each layer of the steel powder bed. The printed green part was then de-binded and densified using Spark Plasma Sintering (SPS). With the use of SPS process, the sintering time was reduced dramatically, restricting the diffusion of carbon in steel and allowing a sharp change in carbon concentration over strips as narrow as ∼ 0.5 mm. Our results show that the porosity was reduced from ∼ 10% to ∼ 1% and the grain sizes from ∼ 100 µm to ∼ 10 µm, when compared to conventionally sintered parts, which in turn improved the yield strength (up to 3.2×), ultimate tensile strength (up to 2.5×) and ductility of the samples (up to 1.9×). Isostrain (Voight composite) and isostress (Reuss composite) samples, composed of high carbon steel and low carbon steel materials, exhibited modulus and strength values in between those of the constituents. However, the ductility and toughness of the site-specific patterned parts were lower than either high carbon or low carbon steel for the selected design parameters, which is in good agreement with predictions from analytical modelling and finite element simulations. This result indicates that the ductility and toughness of a composite are not mathematically bounded by that of its constituent materials, unlike modulus, density and strength.
author2 School of Mechanical and Aerospace Engineering
author_facet School of Mechanical and Aerospace Engineering
Chiang, Po-Ju
Sun, Li
Tan, Li Ping
Singham, Jonathan
Zhao, Yida
Hu, Huanlong
Aik, Khor Khiam
Ramanujan, Raju V.
Jangam, John Samuel Dilip
Lai, Chang Quan
format Article
author Chiang, Po-Ju
Sun, Li
Tan, Li Ping
Singham, Jonathan
Zhao, Yida
Hu, Huanlong
Aik, Khor Khiam
Ramanujan, Raju V.
Jangam, John Samuel Dilip
Lai, Chang Quan
author_sort Chiang, Po-Ju
title Additive manufacturing of carbon steel with site-specific compositions and properties using binder jetting and spark plasma sintering
title_short Additive manufacturing of carbon steel with site-specific compositions and properties using binder jetting and spark plasma sintering
title_full Additive manufacturing of carbon steel with site-specific compositions and properties using binder jetting and spark plasma sintering
title_fullStr Additive manufacturing of carbon steel with site-specific compositions and properties using binder jetting and spark plasma sintering
title_full_unstemmed Additive manufacturing of carbon steel with site-specific compositions and properties using binder jetting and spark plasma sintering
title_sort additive manufacturing of carbon steel with site-specific compositions and properties using binder jetting and spark plasma sintering
publishDate 2024
url https://hdl.handle.net/10356/174652
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