Skip to main content
SpringerLink
Log in

Role of elongational viscosity of feedstock in extrusion-based additive manufacturing of powder-binder mixtures

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The 3D printing of metals and ceramics by the extrusion of a powder/thermoplastic binder feedstock is an extrusion-based additive manufacturing (EAM) technique and has received significant interest. EAM feedstocks are generally characterized by their shear viscosity. A quantitative comparison with the shear flow data, through an estimation of the Trouton ratio, indicates that the extensional viscosities are three orders of magnitude greater than their shear flow viscosity at a comparable shear rate obtained in three different high loaded polymers retained for this study. This experimental study addresses the unsolved issue of the role of elongational viscosity in the modelling of EAM of highly viscous melts. The study was conducted using three feedstocks with a water-soluble binder and high powder loading. The different powder materials used for this study are stainless steel, alumina and zirconia. Initially, the rheological properties of the feedstocks were assessed using capillary rheometers. A pressure drop model based on the shear and elongational components of the viscosity was proposed to predict the extrusion pressure during capillary tests. The model was adapted to develop a specific EAM machine, namely, an EFeSTO, equipped with a pellet extrusion unit. Experimental EAM tests were conducted, and the pressure drops were analytically predicted and experimentally measured. A total of 31 different combinations of extrusion velocities, nozzle diameters, 3D printed shapes and materials were tested through a total 184 experimental runs. The model predicts well the experimental pressures for the steel feedstock, whereas it underestimates the pressure for the two ceramic feedstocks owing to their different thermal properties. The results of this study clearly demonstrate that the pressure, and therefore the material flow during the EAM processes of viscous materials, cannot be modelled well without considering the elongational viscosity.

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. Royer A, Barrière T, Gelin JC (2016) Development and characterization of a metal injection molding bio sourced inconel 718 feedstock based on polyhydroxyalkanoates. Metals (Basel) 6. https://doi.org/10.3390/met6040089

  2. Rane K, Strano M (2019) A comprehensive review of extrusion-based additive manufacturing processes for rapid production of metallic and ceramic parts. Adv Manuf 7:155–173. https://doi.org/10.1007/s40436-019-00253-6

    Article  Google Scholar 

  3. Chen Z, Li Z, Li J, Liu C, Lao C, Fu Y, Liu C, Li Y, Wang P, He Y (2019) 3D printing of ceramics: a review. J Eur Ceram Soc 39:661–687. https://doi.org/10.1016/j.jeurceramsoc.2018.11.013

    Article  Google Scholar 

  4. Nadernezhad A, Unal S, Khani NKB (2019) Material extrusion-based additive manufacturing of structurally controlled poly(lactic acid)/carbon nanotube nanocomposites. Int J Adv Manuf Technol 102:2119–2132

    Article  Google Scholar 

  5. Annoni M, Giberti H, Strano M (2016) Feasibility study of an extrusion-based direct metal additive manufacturing technique. Procedia Manuf 5:916–927. https://doi.org/10.1016/j.promfg.2016.08.079

    Article  Google Scholar 

  6. Strano M, Rane K, Briatico Vangosa F, Di Landro L (2019) Extrusion of metal powder-polymer mixtures: melt rheology and process stability. J Mater Process Technol 273:116250. https://doi.org/10.1016/j.jmatprotec.2019.116250

    Article  Google Scholar 

  7. Hidalgo J, Jiménez-Morales A, Barriere T, Gelin JC, Torralba JM (2015) Capillary rheology studies of INVAR 36 feedstocks for powder injection moulding. Powder Technol 273:1–7. https://doi.org/10.1016/j.powtec.2014.12.027

    Article  Google Scholar 

  8. Dimitri C, Mohamed S, Thierry B, Jean-Claude G (2017) Influence of particle-size distribution and temperature on the rheological properties of highly concentrated Inconel feedstock alloy 718. Powder Technol 322:273–289. https://doi.org/10.1016/j.powtec.2017.08.049

    Article  Google Scholar 

  9. Rane K, Di Landro L, Strano M (2019) Processability of SS316L powder - binder mixtures for vertical extrusion and deposition on table tests. Powder Technol 345:553–562. https://doi.org/10.1016/j.powtec.2019.01.010

    Article  Google Scholar 

  10. Turner BN, Strong RA, Gold S (2014) A review of melt extrusion additive manufacturing processes: I. Process design and modeling. Rapid Prototyp J 20:192–204. https://doi.org/10.1108/RPJ-01-2013-0012

    Article  Google Scholar 

  11. Mackay ME (2018) The importance of rheological behavior in the additive manufacturing technique material extrusion. J Rheol (N Y N Y) 62:1549–1561. https://doi.org/10.1122/1.5037687

    Article  Google Scholar 

  12. Singh P, Shaikh Q, Balla VK, Atre SV, Kate KH (2019) Estimating powder-polymer material properties used in design for metal fused filament fabrication (DfMF 3). JOM. https://doi.org/10.1007/s11837-019-03920-y

  13. Faes M, Vleugels J, Vogeler F, Ferraris E (2016) Extrusion-based additive manufacturing of ZrO2 using photoinitiated polymerization. CIRP J Manuf Sci Technol 14:28–34. https://doi.org/10.1016/j.cirpj.2016.05.002

    Article  Google Scholar 

  14. Kukla C, Gonzalez-Gutierrez J, Duretek I, Schuschnigg S, Holzer C (2017) Effect of particle size on the properties of highly-filled polymers for fused filament fabrication. AIP Conf Proc 1914. https://doi.org/10.1063/1.5016795

  15. Khaliq MH, Gomes R, Fernandes C, Nóbrega J, Carneiro OS, Ferrás LL (2017) On the use of high viscosity polymers in the fused filament fabrication process. Rapid Prototyp J 23:727–735. https://doi.org/10.1108/RPJ-02-2016-0027

    Article  Google Scholar 

  16. Coogan TJ, Kazmer DO (2019) In-line rheological monitoring of fused deposition modeling. J Rheol (N Y N Y) 63:141–155. https://doi.org/10.1122/1.5054648

    Article  Google Scholar 

  17. Thavanayagam G, Pickering KL, Swan JE, Cao P (2015) Analysis of rheological behaviour of titanium feedstocks formulated with a water-soluble binder system for powder injection moulding. Powder Technol 269:227–232. https://doi.org/10.1016/j.powtec.2014.09.020

    Article  Google Scholar 

  18. Khakbiz M, Simchi A, Bagheri R (2005) Analysis of the rheological behavior and stability of 316L stainless steel–TiC powder injection molding feedstock. Mater Sci Eng A 407:105–113. https://doi.org/10.1016/j.msea.2005.06.057

    Article  Google Scholar 

  19. Park SJ, Kim D, Lin D, Park SJ, Ahn S (2017) Rheological characterization of powder mixture including a space holder and its application to metal injection molding. Metals (Basel) 7. https://doi.org/10.3390/met7040120

  20. Huang B, Liang S, Qu X (2003) The rheology of metal injection molding. J Mater Process Technol 137:132–137. https://doi.org/10.1016/S0924-0136(02)01100-7

    Article  Google Scholar 

  21. Samanta SK, Chattopadhyay H, Godkhindi MM (2011) Thermo-physical characterization of binder and feedstock for single and multiphase flow of PIM 316L feedstock. J Mater Process Technol 211:2114–2122. https://doi.org/10.1016/j.jmatprotec.2011.07.008

    Article  Google Scholar 

  22. Huang JC, Leong KS (2002) Shear viscosity, extensional viscosity, and die swell of polypropylene in capillary flow with pressure dependency. J Appl Polym Sci 84:1269–1276. https://doi.org/10.1002/app.10466

    Article  Google Scholar 

  23. Aho J, Syrjälä S (2011) Shear viscosity measurements of polymer melts using injection molding machine with adjustable slit die. Polym Test 30:595–601. https://doi.org/10.1016/j.polymertesting.2011.04.014

    Article  Google Scholar 

  24. Ohtani H, Ellwood K, Pereira G, Chinen T, Selvasekar S (2017) Extensional rheology: new dimension of characterizing automotive fluids. SAE Tech Pap. https://doi.org/10.4271/2017-01-0364

  25. Cogswell FN (1972) Measuring the extensional rheology of polymer melts. Trans Soc Rheol 16:383–403. https://doi.org/10.1122/1.549257

    Article  Google Scholar 

  26. Zatloukal M, Musil J (2009) Analysis of entrance pressure drop techniques for extensional viscosity determination. Polym Test 28:843–853. https://doi.org/10.1016/j.polymertesting.2009.07.007

    Article  Google Scholar 

  27. Hong SY, Broomer M (2000) Economical and ecological cryogenic machining of AISI 304 austenitic stainless steel. Clean Prod Process 2:0157–0166. https://doi.org/10.1007/s100980000073

    Article  Google Scholar 

  28. Arabo EYM (2011) Shear and extensional viscosities of hard wheat flour dough using a capillary rheometer. J Food Eng 103:294–298. https://doi.org/10.1016/j.jfoodeng.2010.10.027

    Article  Google Scholar 

  29. Parenti P, Cataldo S, Grigis A, Covelli M, Annoni M (2019) Implementation of hybrid additive manufacturing based on extrusion of feedstock and milling. Procedia Manuf 34:738–746. https://doi.org/10.1016/j.promfg.2019.06.230

    Article  Google Scholar 

  30. Heaney DF (2012) Handbook of Metal Injection Molding, 1st edn. Woodhead Publishing

  31. Liu ZY, Loh NH, Tor SB, Khor KA (2003) Characterization of powder injection molding feedstock. Mater Charact 49:313–320. https://doi.org/10.1016/S1044-5803(02)00282-6

    Article  Google Scholar 

  32. Vergnes B (2015) Extrusion defects and flow instabilities of molten polymers. Int Polym Process 30:3–28. https://doi.org/10.3139/217.3011

    Article  Google Scholar 

  33. Kishore V, Ajinjeru C, Liu P, Lindahl J, Hassen A, Kunc V et al (2017) Predicting sharkskin instability in extrusion additive manufacturing of reinforced thermoplastics. Solid Free Fabr Symp:1696–1704

  34. Rane K, Petrò S, Strano M (2020) Evolution of porosity and geometrical quality through the ceramic extrusion additive manufacturing process stages. Addit Manuf 32:101038. https://doi.org/10.1016/j.addma.2020.101038

    Article  Google Scholar 

  35. Strano M, Rane K, Herve G, Tosi A (2019) Determination of process induced dimensional variations of ceramic parts, 3d printed by extrusion of a powder-binder feedstock. Procedia Manuf 34:560–565. https://doi.org/10.1016/j.promfg.2019.06.220

    Article  Google Scholar 

  36. Zhou X, Hsieh SJ, Wang JC (2019) Accelerating extrusion-based additive manufacturing optimization processes with surrogate-based multi-fidelity models. Int J Adv Manuf Technol 103:4071–4083

    Article  Google Scholar 

  37. Fotovvati BAE (2019) Size effects on geometrical accuracy for additive manufacturingof Ti-6Al-4V ELI parts. Int J Adv Manuf Technol 104:2951–2959

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Dipartimento di Meccanica, Politecnico di Milano, Via La Masa 1, 20159, Milan, Italy

    Kedarnath Rane & Matteo Strano

  2. CNRS/UFC/ENSMM/UTBM, Department of Applied Mechanics, Univ. Bourgogne Franche-Comté, FEMTO-ST Institute, 25000, Besançon, France

    Thierry Barriere

Authors
  1. Kedarnath Rane
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Thierry Barriere
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Matteo Strano
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Matteo Strano.

Additional information

Publisher’s note

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

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Rane, K., Barriere, T. & Strano, M. Role of elongational viscosity of feedstock in extrusion-based additive manufacturing of powder-binder mixtures . Int J Adv Manuf Technol 107, 4389–4402 (2020). https://doi.org/10.1007/s00170-020-05323-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05323-9

Keywords

Search

Navigation