Additive Manufacturing Two-Phase Binder Process
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Solution Overview
Problem
Current additive manufacturing processes for metal components are time-consuming, expensive, and result in components with high porosity and poor thermal and mechanical properties due to the use of polymer-coated metal powders and subsequent infiltration with low-melting metals.
Innovation Solution
A process involving substrate particles (metallic, vitreous, or ceramic) and a two-phase binder, where the binder is selectively melted using electromagnetic radiation to form layers, allowing for adjustable density and stability through controlled porosity and rheological properties, enabling the production of components with high density and improved thermal and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If selective laser sintering of polymer-coated metal powder is used, then a shaped body can be produced, but the process is time-consuming and expensive
Solution Approach 1:
The patent extracts and removes the polymer binder material from the sintered green body through decomposition and filtration processes. This extraction eliminates the need for complex infiltration steps with low-melting metals, thereby reducing production time and process complexity while maintaining structural integrity
Solution Approach 2:
The manufacturing process is segmented into distinct stages: sintering to form the green body, then separate decomposition and filtration steps to remove the binder. This segmentation allows each step to be optimized independently, reducing overall production time compared to traditional one-step infiltration methods
2Reliability
If infiltration with low-melting metal is performed, then density and stability are increased, but thermal and mechanical properties remain poor
Solution Approach 1:
The patent changes the physical and chemical parameters of the binder material through controlled decomposition. By adjusting decomposition temperature, time, and atmosphere, the binder is converted from a polymer coating into a porous structure that can be selectively removed, creating pathways for metal infiltration without compromising the metal substrate's inherent mechanical properties
Solution Approach 2:
The patent creates a composite structure where the metal substrate particles are embedded in a matrix formed by decomposed binder material. This composite approach allows the metal substrate to provide mechanical strength while the decomposed binder matrix provides structural support and can be selectively removed to create porous structures for improved properties
3Manufacturing precision
If sintering is performed on polymer-coated metal powder, then a shaped body is formed, but high porosity causes nonuniform shrinkage
Solution Approach 1:
The patent performs preliminary sintering to form the green body structure before removing the binder. This preliminary action establishes the basic geometric framework and dimensional relationships, allowing subsequent binder removal to proceed without causing nonuniform shrinkage. The green body structure acts as a template that guides the final dimensional accuracy
4Strength
If a two-phase binder is used, then density and strength are improved, but the process complexity increases
Solution Approach 1:
The patent uses a two-phase binder system where each phase serves a specific local function: one phase provides binding strength during sintering, while the other phase is designed for selective removal. This local differentiation of binder properties allows the system to provide both structural integrity during manufacturing and pathways for subsequent processing, without requiring complex external equipment
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process allows for the simple, flexible, and economical production of components with adjustable density and stability, achieving a high-density, pore-free microstructure and sufficient strength, reducing production costs and improving thermal and mechanical properties.
Implementation Method 1
a first layer of substrate particles and binder is produced and the binder is selectively melted by means of electromagnetic radiation to produce a shaped part layer
Implementation Method 2
the shaped part is subsequently sintered to obtain the component. The substrate particles are joined together and form the component
Data Source
AI summary
A process for the additive manufacture of a metallic and/or vitreous and/or ceramic component, a mixture of substrate particles and an at least two-phase binder is firstly provided. The mixture is preferably provided as composite particles, so that the substrate particles adhere to one another by the at least two-phase binder. The mixture is selectively melted layerwise by electromagnetic radiation so that a shaped part is additively produced. The shaped part is taken out from the mixture which has not been melted and the at least two-phase binder is subsequently removed, preferably successively. The process produces a microporous shaped part which after sintering leads to a component having a desired density and a desired mechanical and/or thermal stability.