Skip to main content
SpringerLink
Log in

Process Sensitivity and Significant Parameters Investigation in Metal Fused Filament Fabrication of Ti-6Al-4V

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

Metal fused filament fabrication (MF3) combines fused filament fabrication and sintering processes to fabricate complex metal components. To design for MF3, an understanding of part geometry, printing parameters and material properties' effects on processability, part quality and ensuing properties is required. However, such investigation is a complex problem having several linked geometry, process and material variables to be considered that influence the process outcome. Moreover, such investigations through the experimental trial-and-error approach are costly and time-consuming, and sometimes not even feasible due to so many input variables involved. This study investigated the sensitivity of key output parameters toward each of the input parameters in MF3. FEA-based thermomechanical process simulations were used to estimate the process outcome in response to variable inputs, and a systematic procedure for sensitivity analysis has been successfully developed for the printing phase of the MF3 process. Dimensionless sensitivity values for all output parameters were calculated in the response of each input parameter, which allows parameters with different units to be compared quantitatively with a single yardstick. Moreover, three different part geometries were studied to identify how the process sensitivity varies with part geometry. For each output parameter, the most influential input parameters were identified from the whole set of input parameters and their influence trends were evaluated for different part geometries. The present sensitivity analysis procedure is expected to be an invaluable tool not only for process parameters optimization but also for the development of material and part geometry for MF3, hence enabling design for MF3 (DfMF3).

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1.
Fig. 2.
Fig. 3.
Fig. 4.
Fig. 5.
Fig. 6.
Fig. 7.
Fig. 8.
Fig. 9.
Fig. 10.
Fig. 11.

Similar content being viewed by others

References

  1. J.G. Gutierrez, S. Cano, S. Schuschnigg, C. Kukla, J. Sapkota and C. Holzer, Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives, Materials, 2018, 11(5), p 840.

    Article  Google Scholar 

  2. P. Singh, Q. Shaikh, V.K. Balla, S.V. Atre and K.H. Kate, Estimating Powder-Polymer Material Properties Used in Design for Metal Fused Filament Fabrication (DfMF3), JOM, 2020, 72, p 485–495.

    Article  Google Scholar 

  3. Y. Thompson, J.G. Gutierrez, C. Kukla and P. Felfer, Fused Filament Fabrication, Debinding and Sintering as a Low Cost Additive Manufacturing Method of 316L Stainless Steel, Addit. Manuf., 2019, 30, p 100861.

    CAS  Google Scholar 

  4. G. Wu, N.A. Langrana, R. Sadanji and S. Danforth, Solid Freeform Fabrication of Metal Components Using Fused Deposition of Metals, Mater. Des., 2002, 23(1), p 97–105.

    Article  Google Scholar 

  5. W. Lengauer, I. Duretek, M. Fürst, V. Schwarz, J.G. Gutierrez, S. Schuschnigg, C. Kukla, M. Kitzmantel, E. Neubauer, C. Lieberwirth and V. Morrison, Fabrication and Properties of Extrusion-Based 3D-Printed Hardmetal and Cermet Components, Int. J. Refract Metal Hard Mater., 2019, 82, p 141–149.

    Article  CAS  Google Scholar 

  6. L. Ren, X. Zhou, Z. Song, C. Zhao, Q. Liu, J. Xue and X. Li, Process Parameter Optimization of Extrusion-Based 3D Metal Printing Utilizing PW–LDPE–SA Binder System, Materials, 2017, 10(3), p 305.

    Article  Google Scholar 

  7. S. Ahn, S.J. Park, S. Lee, S.V. Atre and R.M. German, Effect of Powders and Binders on Material Properties and Molding Parameters in Iron and Stainless Steel Powder Injection Molding Process, Powder Technol., 2009, 193, p 162–169.

    Article  CAS  Google Scholar 

  8. A. Armillotta, M. Bellotti and M. Cavallaro, Warpage of FDM Parts: Experimental Tests and Analytic Model, Robot. Comput. Integr. Manuf., 2018, 50, p 140–152.

    Article  Google Scholar 

  9. P. Parandoush and D. Lin, A Review on Additive Manufacturing of Polymer-Fiber Composites, Compos. Struct., 2017, 182, p 36–53.

    Article  Google Scholar 

  10. R.Q. de Macedo and R.T. Ferreira, Residual thermal stress in fused deposition modelling, in ABCM International Congress of Mechanical Engineering, 24th edn., December 3–8, 2017, Curitiba, Brazil, COBEM-2017-0124

  11. M.D. Espin, J.M. Forcada, A.A. Granada, J. Llumà, S. Borros and G. Reyes, Mechanical Property Characterization and Simulation of Fused Deposition Modeling Polycarbonate Parts, Mater. Des., 2015, 83, p 670–677.

    Article  Google Scholar 

  12. H. Xia, J. Lu, S. Dabiri and G. Tryggvason, Fully Resolved Numerical Simulations of Fused Deposition Modeling. Part I: Fluid Flow, Rapid Prototyp. J., 2018, 24(2), p 463–476.

    Article  Google Scholar 

  13. Y. Zhou, G. Xiong, T. Nyberg, and D. Liu, Temperature analysis in the fused deposition modeling process, in International Conference on Information Science and Control Engineering, 3rd edn., July 8–10, 2016, Beijing, China, 978-1-5090-2534-3/16

  14. S.F. Costa, F.M. Duarte and J.A. Covas, Thermal Conditions Affecting Heat Transfer in FDM/FFE: A Contribution Towards the Numerical Modelling of the Process, Virtual Phys. Prototyp., 2015, 10(1), p 35–46.

    Article  Google Scholar 

  15. Y. Zhang and Y.K. Chou, 3D FEA simulations of fused deposition modeling process, in ASME International Conference on Manufacturing Science and Engineering, 1st edn., October 8–11, 2006, 2006, Ypsilanti, MI, USA, MSEC2006-21132

  16. A. Cattenone, S. Morganti, G. Alaimo and F. Auricchio, Finite Element Analysis of Additive Manufacturing Based on Fused Deposition Modeling (FDM): Distortions Prediction and Comparison with Experimental Data, J. Manuf. Sci. Eng., 2019, 141(011010), p 1–17.

    Google Scholar 

  17. B. Barmore, Fused Filament Fabrication of Filled Polymers for Metal Additive Manufacturing. Master’s Thesis, Mechanical Engineering, Oregon State University, 2016

  18. T.W. Kerekes, H. Lim, W.Y. Joe and G.J. Yun, Characterization of Process–Deformation/Damage Property Relationship of Fused Deposition Modeling (FDM) 3D-Printed Specimens, Addit. Manuf., 2019, 25, p 532–544.

    Google Scholar 

  19. F. Górski, W. Kuczko and R. Wichniarek, Influence of Process Parameters on Dimensional Accuracy of Parts Manufactured Using Fused Deposition Modelling Technology, Adv. Sci. Technol., 2013, 7(19), p 27–35.

    Google Scholar 

  20. J. Giannatsis, K. Sofos, V. Canellidis, D. Karalekas, and V. Dedoussis, Investigating the influence of build parameters on the mechanical properties of FDM parts, in Innovative Developments in Virtual and Physical Prototyping, Dec 2011 (Taylor & Francis Group, London, 2011) ISBN 978-0-415-68418-7

  21. G. Jothibabua and S.K. Gurunathanb, Surrogate Based Sensitivity Analysis of Part Strength due to Process Parameters in Fused Deposition Modelling, Proc. Comput. Sci., 2018, 133, p 772–778.

    Article  Google Scholar 

  22. B.H. Lee, J. Abdullah and Z.A. Khan, Optimization of Rapid Prototyping Parameters for Production of Flexible ABS Object, J. Mater. Process. Technol., 2005, 169, p 54–61.

    Article  CAS  Google Scholar 

  23. E.R. Fitzharris, N. Watanabe, D.W. Rosen and M.L. Shofner, Effects of Material Properties on Warpage in Fused Deposition Modeling Parts, Int. J. Adv. Manuf. Technol., 2018, 95, p 2059–2070.

    Article  Google Scholar 

  24. B. Vasudevarao, D.P. Natarajan, M. Henderson, and A. Razdan, Sensitivity of RP Surface Finish to Process Parameter Variation, https://www.researchgate.net/publication/2467464

  25. S.V. Atre, S.J. Park, R. Zauner and R.M. German, Process Simulation of Powder Injection Moulding: Identification of Significant Parameters During Mould Filling Phase, Powder Metall., 2007, 50(1), p 76–85.

    Article  CAS  Google Scholar 

  26. A.E. Moumen, M. Tarfaoui and K. Lafdi, Modelling of the Temperature and Residual Stress Fields During 3D Printing of Polymer Composites, Int. J. Adv. Manuf. Technol., 2019, 104, p 1661–1676.

    Article  Google Scholar 

  27. e-Xstream, Digimat-AM Simulation Solution for Additive Manufacturing, https://www.e-xstream.com/product/digimat-am. Accessed 15 Sept 2020

  28. P. Singh, V.K. Balla, A. Tofangchi, S.V. Atre and K.H. Kate, Printability Studies of Ti-6Al-4V by Metal Fused Filament Fabrication (MF3), Int. J. Refract Metal Hard Mater., 2020, 91, p 105249.

    Article  CAS  Google Scholar 

  29. Q. Sun, G.M. Rizvi, C.T. Bellehumeur and P. Gu, Effect of Processing Conditions on the Bonding Quality of FDM Polymer Filaments, Rapid Prototyp. J., 2008, 14(2), p 72–80.

    Article  Google Scholar 

  30. C. Bellehumeur, L. Li, Q. Sun and P. Gu, Modeling of Bond Formation Between Polymer Filaments in the Fused Deposition Modeling Process, SME J. Manuf. Process., 2004, 6, p 2.

    Google Scholar 

Download references

Acknowledgment

The autors acknowledge the financial support from the Minority Business Development Agency, USA (MBDA) and the National Aeronautics and Space Administration (NASA). The authors also recognize MSC Software (A Hexagon company) for providing the Digimat simulation tool used in this study.

Author information

Authors and Affiliations

  1. Materials Innovation Guild, University of Louisville, Louisville, KY, 40208, USA

    Mohammad Qasim Shaikh, Kunal H. Kate & Sundar V. Atre

  2. e-Xstream Engineering, MSC Software Corp (Hexagon), Newport Beach, CA, 92660, USA

    Pierre-Yves Lavertu

Authors
  1. Mohammad Qasim Shaikh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Pierre-Yves Lavertu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Kunal H. Kate
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Sundar V. Atre
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Sundar V. Atre.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

This invited article is part of a special topical focus in the Journal of Materials Engineering and Performance on Additive Manufacturing. The issue was organized by Dr. William Frazier, Pilgrim Consulting, LLC; Mr. Rick Russell, NASA; Dr. Yan Lu, NIST; Dr. Brandon D. Ribic, America Makes; and Caroline Vail, NSWC Carderock.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Shaikh, M.Q., Lavertu, PY., Kate, K.H. et al. Process Sensitivity and Significant Parameters Investigation in Metal Fused Filament Fabrication of Ti-6Al-4V. J. of Materi Eng and Perform 30, 5118–5134 (2021). https://doi.org/10.1007/s11665-021-05666-8

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-021-05666-8

Keywords

Search

Navigation