热脱脂黏结金属沉积增材制造金属薄壁结构制备及其吸能特性

Fabrication and energy absorption characteristics of thin-walled metal structures fabricated by thermal debinding bound metal deposition additive manufacturing

摘要

黏结金属沉积（bound metal deposition，BMD）制造金属部件的过程中，仅采用热脱脂去除黏结剂是一种安全和环保的脱脂方法。通过降低样品壁厚实现用热脱脂方法有效去除样品中的黏结剂，并对适用于热脱脂黏结金属沉积增材的结构及烧结后金属件的能量吸收特性进行深入分析。结果表明壁厚为0.45 mm的薄壁结构热脱脂后没有产生明显的变形、起泡和裂纹。所制备的内部具有弯曲薄壁的结构在热脱脂后没有产生明显变形、起泡和裂纹，并在烧结后形成仅存在少量微米级孔隙的金属件，同时具有优异的能量吸收效果。金属薄壁结构在压缩过程的总吸能为19.2 J，比吸能为6.6 J/g，比现有报道中二维金属薄壁结构（主要为蜂窝结构）的比吸能高187%以上。

Abstract

Thermal debinding is a safe and environmentally friendly debinding method for removing the binders during the process of metal parts manufacturing by bound metal deposition (BMD). In this study, the binders in the sample are effectively removed using thermal debinding method by reducing the sample wall thickness. The structures applicable to thermal debinding in bound metal deposition additive manufacturing and the energy absorption characteristics of sintered metal parts are deeply analysed. The results show that the sheet structure with a wall thickness of 0.45 mm does not produce obvious deformation, blistering and cracks after thermal debinding. The prepared thin-walled structure with curved thin walls in the interior does not induce obvious deformation, blistering or cracks after thermal debinding and the thin-walled metal structure after sintering only has small number of micron pores. The thin-walled metal structure has good energy absorption effects. The energy absorption is 19.2 J and the specific energy absorption is 6.6 J/g of the thin-walled metal structure during the compression process, which is 187% higher than the specific energy absorption of two-dimensional thin-walled metal structures (mainly honeycomb structures) in the results of the published literature.

关键词

黏结金属沉积 / 热脱脂 / 薄壁结构 / 能量吸收

Key words

bound metal deposition / thermal debinding / thin-walled structure / energy absorption

参考文献

[1] BANKAPALLI N K, GUPTA V, SAXENA P, et al. Filament fabrication and subsequent additive manufacturing, debinding, and sintering for extrusion—based metal additive manufacturing and their applications: a review[J].Composites Part B, 2023, 264: 110915.

[2] NURHUDAN A I, SUPRIADI S, WHULANZA Y, et al. Additive manufacturing of metallic based on extrusion process: a review[J].Journal of Manufacturing Processes, 2021, 66: 228-237.

[3] SINGH G, MISSIAEN J M, BOUVARD D, et al. Additive manufacturing of 17—4 PH steel using metal injection molding feedstock: analysis of 3D extrusion printing, debinding and sintering[J].Additive Manufacturing, 2021, 47: 102287.

[4] GABILONDO M, CEARSOLO X, ARRUE M, et al. Influence of build orientation, chamber temperature and infill pattern on mechanical properties of 316L parts manufactured by bound metal deposition[J].Materials, 2022, 15(3): 1183.

[5] PASCUAL—GONZÁLEZ C, SAN MARTÍN P, LIZARRALDE I, et al. Post—processing effects on microstructure, interlaminar and thermal properties of 3D printed continuous carbon fibre composites[J].Composites Part B, 2021, 210: 108652.

[6] ZHANG H Q, CHEN J Y, YANG D M. Fibre misalignment and breakage in 3D printing of continuous carbon fibre reinforced thermoplastic composites[J].Additive Manufacturing, 2021, 38: 101775.

[7] LOTFIZAREI Z, MOSTAFAPOUR A, BARARI A, et al. Overview of debinding methods for parts manufactured using powder material extrusion[J].Additive Manufacturing, 2023, 61: 103335.

[8] BJØRHEIM F, La TORRACA LOPEZ I M . Tension testing of additively manufactured specimens of 17—4 PH processed by bound metal deposition[J].IOP Conference Series: Materials Science and Engineering, 2021, 1201(1): 012037.

[9] RENUKARADHYA K G L. Metal filament 3D printing of SS316L—focusing on the printing process[D]. Stockholm:KTH Royal Institute of Technology, 2019.

[10] SADAF M, BRAGAGLIA M, NANNI F. A simple route for additive manufacturing of 316L stainless steel via fused filament fabrication[J].Journal of Manufacturing Processes, 2021, 67: 141-150.

[11] SÆTERBØ M, SOLVANG W D. Evaluating the cost competitiveness of metal additive manufacturing—a case study with metal material extrusion[J].CIRP Journal of Manufacturing Science and Technology, 2023, 45: 113-124.

[12] LIU B, WANG Y X, LIN Z W, et al. Creating metal parts by fused deposition modeling and sintering[J].Materials Letters, 2020, 263: 127252.

[13] ZHANG Y Z, BAI S Y, RIEDE M, et al. A comprehensive study on fused filament fabrication of Ti—6Al—4V structures[J].Additive Manufacturing, 2020, 34: 101256.

[14] THOMPSON Y, GONZALEZ—GUTIERREZ J, KUKLA C, et al. Fused filament fabrication, debinding and sintering as a low cost additive manufacturing method of 316L stainless steel[J].Additive Manufacturing, 2019, 30: 100861.

[15] HEANEY E F. Handbook of metal injection molding[M]. Cambridge: Woodhead Publishing,2012.

[16] GERMAN R. Progress in titanium metal powder injection molding[J].Materials, 2013, 6(8): 3641-3662.

[17] ENNETI R K, PARK S J, GERMAN R M, et al. Review: thermal debinding process in particulate materials processing[J].Materials and Manufacturing Processes, 2012, 27(2): 103-118.

[18] LI S H, DENG H W, LAN X Q, et al. Developing cost—effective indirect manufacturing of H13 steel from extrusion—printing to post—processing[J].Additive Manufacturing, 2023, 62: 103384.

[19] XIE H H, JIANG J, YANG X F, et al. Theory and practice of rapid and safe thermal debinding in ceramic injection molding[J].International Journal of Applied Ceramic Technology, 2020, 17(3): 1098-1107.

[20] LI Y M, LIU S J, QU X H, et al. Thermal debinding processing of 316L stainless steel powder injection molding compacts[J].Journal of Materials Processing Technology, 2003, 137(1/2/3): 65-69.

[21] 康颖安, 张俊彦, 谭加才. 相对密度对泡沫铝力学性能和能量吸收性能的影响[J].功能材料, 2006, 37(2): 247-249.

[22] KANG Y A, ZHANG J Y, TAN J C. Effect of relative density on the compressive property and energy absorption capacity of aluminum foams[J].Journal of Functional Materials, 2006, 37(2): 247-249.

[23] WU Y Z, FANG J G, WU C, et al. Additively manufactured materials and structures: a state—of—the—art review on their mechanical characteristics and energy absorption[J].International Journal of Mechanical Sciences, 2023, 246: 108102.

[24] GAO G J, WANG S. Crashworthiness of passenger rail vehicles: a review[J].International Journal of Crashworthiness, 2019, 24(6): 664-676.

[25] ZHANG X, ZHANG H. Theoretical and numerical investigation on the crush resistance of rhombic and kagome honeycombs[J].Composite Structures, 2013, 96: 143-152.

[26] YANG X F, XI X L, PAN Q F, et al. In—plane dynamic crushing of a novel circular—celled honeycomb nested with petal—shaped mesostructure[J].Composite Structures, 2019, 226: 111219.

[27] HU L L, ZHOU M Z, DENG H. Dynamic crushing response of auxetic honeycombs under large deformation: theoretical analysis and numerical simulation[J].Thin—Walled Structures, 2018, 131: 373-384.

[28] IVAÑEZ I, FERNANDEZ—CAÑADAS L M, SANCHEZ—SAEZ S. Compressive deformation and energy—absorption capability of aluminium honeycomb core[J].Composite Structures, 2017, 174: 123-133.

[29] DUAN S Y, TAO Y, LEI H S, et al. Enhanced out—of—plane compressive strength and energy absorption of 3D printed square and hexagonal honeycombs with variable—thickness cell edges[J].Extreme Mechanics Letters, 2018, 18: 9-18.

[30] YIN H F, ZHANG W Z, ZHU L C, et al. Review on lattice structures for energy absorption properties[J].Composite Structures, 2023, 304: 116397.

[31] ZHANG D H, FEI Q G, ZHANG P W. In—plane dynamic crushing behavior and energy absorption of honeycombs with a novel type of multi—cells[J].Thin—Walled Structures, 2017, 117: 199-210.

[32] YIN H F, HUANG X F, SCARPA F, et al. In—plane crashworthiness of bio—inspired hierarchical honeycombs[J].Composite Structures, 2018, 192: 516-527.

基金资助

辽宁省“兴辽英才”计划项目(XLYC2203071)

辽宁省应用基础研究计划项目(2023JH2/101300149)