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<p>The potential for performing selective component lightweighting via latticing using the binder jetting additive manufacturing (BJAM) process was investigated as a method toward functional lightweighting, with the goal of characterizing and understanding how an applied lattice architecture influences a component’s bulk geometric fidelity response and densification behaviour (pore fraction, morphology, composition). To this effect, a region-specific latticing approach was employed, where select solid regions in a component were latticed with a custom honeycomb lattice architecture, supporting solid (unlatticed) regions. Sizeable test coupons were printed from a water-atomized low-alloy steel powder of similar composition to MPIF FL-4405, then sintered at 1425&#xa0;°C under a reducing atmosphere of 5% hydrogen–95% nitrogen. Geometric shape fidelity, density, remnant pore morphology, and carbon composition were quantified for these latticed coupons and compared to fully solid (unlatticed) specimens. This work demonstrated successful near-net-shape fabrication of large, latticed components, without loss of geometric shape fidelity, and the ability to sinter the solid regions of these structures to near-full density (99.81 ± 0.13%). Abnormally high carbon retention (0.655 ± 0.014% C) was found to result in significant porosity defects in fully solid samples, while latticed samples were comparatively unaffected (0.631 ± 0.010% C), as confirmed with LECO analysis and energy dispersive X-ray spectroscopy. Complete removal of residual binder was identified as a key factor in achieving fully dense components of this size, wherein the lattice architecture was revealed to improve bulk solid region densification by promoting binder removal via an effective decrease in part surface-to-core distance and more efficient gas outflow.</p>

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Toward functional lightweighting in binder jetting additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年1月28日

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  • Daniel R. Juhasz,
  • Mohsen K. Keshavarz,
  • Amin Molavi-Kakhki,
  • Mihaela Vlasea

摘要

The potential for performing selective component lightweighting via latticing using the binder jetting additive manufacturing (BJAM) process was investigated as a method toward functional lightweighting, with the goal of characterizing and understanding how an applied lattice architecture influences a component’s bulk geometric fidelity response and densification behaviour (pore fraction, morphology, composition). To this effect, a region-specific latticing approach was employed, where select solid regions in a component were latticed with a custom honeycomb lattice architecture, supporting solid (unlatticed) regions. Sizeable test coupons were printed from a water-atomized low-alloy steel powder of similar composition to MPIF FL-4405, then sintered at 1425 °C under a reducing atmosphere of 5% hydrogen–95% nitrogen. Geometric shape fidelity, density, remnant pore morphology, and carbon composition were quantified for these latticed coupons and compared to fully solid (unlatticed) specimens. This work demonstrated successful near-net-shape fabrication of large, latticed components, without loss of geometric shape fidelity, and the ability to sinter the solid regions of these structures to near-full density (99.81 ± 0.13%). Abnormally high carbon retention (0.655 ± 0.014% C) was found to result in significant porosity defects in fully solid samples, while latticed samples were comparatively unaffected (0.631 ± 0.010% C), as confirmed with LECO analysis and energy dispersive X-ray spectroscopy. Complete removal of residual binder was identified as a key factor in achieving fully dense components of this size, wherein the lattice architecture was revealed to improve bulk solid region densification by promoting binder removal via an effective decrease in part surface-to-core distance and more efficient gas outflow.