Mechanized spreading of ceramic powder layers for additive manufacturing characterized by transmission x-ray imaging: Influence of powder feedstock and spreading parameters on powder layer density

Influence of Alumina Grade on Sintering Properties and Possible Application in Binder Jetting Additive Technology

Alumina is one of the most popular ceramic materials widely used in both tooling and construction applications due to its low production cost, and high properties. However, the final properties of the product depend not only on the purity of the powder, but also, e.g., on its particle size, specific surface area, and the production technology used. These parameters are particularly important in the case of choosing additive techniques for the production of details. Therefore, the article presents the results of comparing five grades of Al₂O₃ ceramic powder. Their specific surface area (via Brunauer-Emmett-Teller (BET) and Barrett-Joyner-Halenda (BJH) methods), particle size distribution, and phase composition by X-ray diffraction (XRD) were determined. Moreover, the surface morphology was characterized by the scanning electron microscopy (SEM) technique. The discrepancy between generally available data and the results obtained from measurements has been indicated. Moreover, the method of spark plasma sintering (SPS), equipped with the registration system of the position of the pressing punch during the process, was used to determine the sinterability curves of each of the tested grades of Al₂O₃ powder. Based on the obtained results, a significant influence of the specific surface area, particle size, and the width of their distribution at the beginning of the Al₂O₃ powder sintering process was confirmed. Furthermore, the possibility of using the analyzed variants of powders for binder jetting technology was assessed. The dependence of the particle size of the powder used on the quality of the printed parts was demonstrated. The procedure presented in this paper, which involves analyzing the properties of alumina varieties, was used to optimize the Al₂O₃ powder material for binder jetting printing. The selection of the best powder in terms of technological properties and good sinterability makes it possible to reduce the number of 3D printing processes, which makes it more economical and less time-consuming.

Investigation of the Effects of Roller Spreading Parameters on Powder Bed Quality in Selective Laser Sintering

Powder spreading is one of crucial steps in selective laser sintering (SLS), which controls the quality of the powder bed and affects the quality of the printed parts. It is not advisable to use empirical methods or trial-and-error methods that consume lots of manpower and material resources to match the powder property parameters and powder laying process parameters. In this paper, powder spreading in realistic SLS settings was simulated using a discrete element method (DEM) to investigate the effects of the powder's physical properties and operating conditions on the bed quality, characterized by the density characteristics, density uniformity, and flatness of the powder layer. A regression model of the powdering quality was established based on the response surface methodology (RSM). The relationship between the proposed powdering quality index and the research variables was well expressed. An improved multi-objective optimization algorithm of the non-dominated sorting genetic algorithm II (NSGA-II) was used to optimize the powder laying quality of nylon powder in the SLS process. We provided different optimization schemes according to the different process requirements. The reliability of the multi-objective optimization results for powdering quality was verified via experiments.