3D Printing of high melting iron alloys using metal-fused deposition modeling: a comprehensive review

by Tanya Fosdal | Sep 14, 2023 | research papers

“Advancements in additive manufacturing (AM) have allowed for a transition in the manufacturing industry. The ability to print solid metal parts for use in prototypes, custom tooling, and fast replacement parts has driven advancements in the manufacturing sector. Material extrusion additive manufacturing processes such as fused deposition modeling (FDM) is a common AM processes in the world of thermoplastics and it is being developed in the field of metal additive manufacturing. Metal FDM (FDMm) process provides a low cost, customizable, and user-friendly printing experience while still delivering high printing tolerances. While there are many materials that can be printed using FDM technologies, process parameters vary across materials resulting in inconsistent process parameters across the industry. This review paper focuses on the techniques and parameters performed by various researchers for the printing, debinding, and sintering of FDM printed 316L Stainless Steel, 17-4PH Stainless Steel and high melt Iron alloy filaments.”

Full paper published to Springer Nature Link 14 September 2023: https://link.springer.com/article/10.1007/s00170-023-12189-0

Overview of Metal Additive Manufacturing Techniques

Metal additive manufacturing encompasses various techniques that enable the production of complex geometries with high precision. Among these, methods like Direct Metal Laser Sintering (DMLS) and Electron Beam Melting (EBM) are prominent, each offering unique advantages in terms of material properties and production speed.

For instance, DMLS is known for its ability to produce intricate parts with minimal waste, making it suitable for aerospace and medical applications. In contrast, EBM uses an electron beam to melt metal powder, which can lead to superior mechanical properties in the final product, particularly when working with high melting alloys.

Key Parameters for Successful Metal FDM Printing

Understanding the key parameters involved in metal Fused Deposition Modeling (FDM) is crucial for achieving optimal results. Factors such as extrusion temperature, print speed, and layer thickness play a significant role in determining the quality and mechanical properties of the printed parts.

For example, maintaining an optimal extrusion temperature ensures that the filament flows smoothly, while adjusting the print speed can help reduce defects like warping or delamination. Additionally, experimenting with layer thickness can influence the surface finish and strength of the final product, making it essential to fine-tune these settings based on the specific material being used.

Debinding and Sintering Processes Explained

Debinding and sintering are critical steps in the metal 3D printing workflow, particularly for FDM processes. Debinding involves removing the binder material used in the filament, while sintering is the process of heating the printed part to fuse the metal particles together, enhancing its density and mechanical properties.

Typically, debinding can be achieved through thermal or solvent methods, each with its own set of advantages and challenges. Following debinding, sintering at precise temperatures is essential to achieve the desired material characteristics, such as strength and ductility, particularly for high melting iron alloys which require careful temperature control to avoid defects.

Applications of High Melting Iron Alloys in Industry

High melting iron alloys are increasingly being utilized in various industrial applications due to their superior mechanical properties and resistance to high temperatures. Industries such as aerospace, automotive, and energy are leveraging these materials for components that demand durability and reliability under extreme conditions.

For instance, in aerospace, high melting iron alloys can be found in turbine components where heat resistance is critical. Similarly, in the automotive sector, these materials are employed in engine parts that require both strength and thermal stability, showcasing the versatility and importance of high melting iron alloys in modern manufacturing.