Binder jet 3D printing of H13 tool steel for applications in injection moulding

• Main Author: Woo, Justin Kai Jie
• Other Authors: Seah Leong Keey
• Format: Final Year Project
• Language: English
• Published: Nanyang Technological University 2024
• Subjects: Engineering; Binder jet 3D printing; H13 tool steel; Injection moulding; Additive manufacturing
• Online Access: https://hdl.handle.net/10356/176125
• Institution: Nanyang Technological University

The modern manufacturing landscape increasingly relies on Additive Manufacturing (AM) technologies to meet the demands for complex, high-performance components. This study focuses on optimising the Binder Jet 3D Printing (BJ3DP) process to produce porous H13 Tool Steel parts suitable for injection moulding applications, aiming to bridge the gap between AM capabilities and tooling requirements in the industry. The primary objective of this study is to investigate and optimise BJ3DP parameters to achieve effective porosity control and enhance mechanical properties of H13 Tool Steel parts, ultimately creating porous metallic tooling inserts suitable for injection moulding. Specific emphasis is placed on understanding the influence of printing and post-printing parameters on porosity, microstructure, material hardness, and tensile mechanical properties. The study involves systematic variations in BJ3DP parameters such as binder set time and binder dry time, followed by Solid State Sintering (SSS) to enhance part density and strength. Porosity calculations, microstructure analysis using scanning electron microscopy (SEM), Vickers hardness tests, and tensile tests are conducted to evaluate part performance and benchmark against conventionally manufactured dense tool steel parts. Through experimental iterations and analysis, the study successfully achieves porosity control and improves mechanical properties of BJ3DP H13 Tool Steel parts. The optimised BJ3DP process parameters demonstrate the feasibility of producing porous metallic tooling inserts suitable for injection moulding applications. The study highlights the potential of AM technologies in toolmaking, offering enhanced design flexibility, reduced lead times, and cost-effective production of complex tooling components.