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The effect of printing parameters on sintered properties of extrusion-based additively manufactured stainless steel 316L parts

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Abstract

Extrusion-based additive manufacturing (EAM) is a relatively new process developed for the production of complex metallic and ceramic parts needed in smaller quantities. The debinding and sintering step of EAM is adopted from a well-known powder injection molding process. However, the 3D printing step needs special consideration to make EAM competent in the era of rapid manufacturing. This study is intended to investigate the effect of common printing parameters on the microstructure and mechanical properties of sintered stainless steel 316L (SS316L) parts manufactured through the EAM process. Part orientation (Ori), extrusion velocity (Ve), and layer height (h) were changed in experimental runs by following a full factorial design. Extrusion pressure as an indicator of melt stability and a grey relational grade as a combined response of sintered properties were analyzed against varying printing parameters. Physical characteristics measured during debinding and sintering show near isotopic shrinkage and the process is stable. Metallographic characterization in terms of porosity and grain size indicated minor differences when Ve and h were altered. Sintered parts showed improved properties when printed with vertical part orientation and h = 0.5 mm, whereas Ve which contributes significantly to the build-up rate was found to be responsible for melt stability. Ve at 12.5 mm/s exhibited melt stability and higher sintered properties.

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Abbreviations

PIM/MIM :

powder/metal injection molding

AM:

additive manufacturing

FDM:

fused deposition modeling

EAM:

extrusion-based additive manufacturing

FDMet :

fused deposition of metals

DLD:

direct laser deposition

SLM:

selective laser melting

D n :

nozzle diameter

V e :

extrusion velocity

V t :

table velocity

Engg_ε:

engineering strain

Engg_σ:

engineering stress

σ f :

flexural strength/modulus of rupture

h :

layer height

Ori:

part orientation

ρ :

density

E :

elastic modulus

HV:

Vickers’s hardness number

H :

horizontal orientation

V :

vertical orientation

CVP_Exp :

coefficient of variation for extrusion pressure

GRGP :

grade relational grade for sintered properties

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Authors and Affiliations

  1. Dipartimento di Meccanica, Politecnico di Milano, Via La Masa 1, Milan, Italy

    Waqar Hassan, Muhammad Asad Farid, Anna Tosi, Kedarnath Rane & Matteo Strano

Authors
  1. Waqar Hassan
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  2. Muhammad Asad Farid
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  3. Anna Tosi
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  4. Kedarnath Rane
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  5. Matteo Strano
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Contributions

Waqar Hassan: conceptualization, methodology, software, and writing-original draft. Muhammad Asad Farid: resources, visualization, experimentation, and investigation. Anna Tosi: resources and investigation. Kedarnath Rane: resources, visualization, and investigation. Matteo Strano: formal analysis, supervision, and writing-review & editing.

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Correspondence to Waqar Hassan.

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Highlights

• Identification of influential printing parameters for extrusion-based additively manufactured stainless steel 316L parts.

• The multi-step extrusion-based additive manufacturing (EAM) process was optimized based on extrusion pressure and grey relational grade (GRGp) for sintered properties as the responses.

• Weight and longitudinal shrinkage show negligible changes after sintering.

• Even though there is no clear trend of GRGP with increasing extrusion velocity (Ve). The optimal combination of considered printing parameters in EAM are Ve = 12.5 mm/s and h = 0.5 mm.

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Hassan, W., Farid, M.A., Tosi, A. et al. The effect of printing parameters on sintered properties of extrusion-based additively manufactured stainless steel 316L parts. Int J Adv Manuf Technol 114, 3057–3067 (2021). https://doi.org/10.1007/s00170-021-07047-w

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  • DOI: https://doi.org/10.1007/s00170-021-07047-w

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