Demonstration and benchmarking of a novel powder sheet additive manufacturing approach with austenitic steel

Wenyou Zhang; Silvia Marola; Seán McConnell; Zhe Cai; JanMell Dugenio; Ming Li; William M. Abbott; Asli Coban; Arnoldas Sasnauskas; Shuo Yin; Ramesh Padamati Babu; Wajira Mirihanage; Riccardo Casati; Rocco Lupoi

Materials & Design (Sep 2024)

Demonstration and benchmarking of a novel powder sheet additive manufacturing approach with austenitic steel

Wenyou Zhang,
Silvia Marola,
Seán McConnell,
Zhe Cai,
JanMell Dugenio,
Ming Li,
William M. Abbott,
Asli Coban,
Arnoldas Sasnauskas,
Shuo Yin,
Ramesh Padamati Babu,
Wajira Mirihanage,
Riccardo Casati,
Rocco Lupoi

Affiliations

Wenyou Zhang: Trinity College Dublin, The University of Dublin, Department of Mechanical, Manufacturing & Biomedical Engineering, Dublin, Ireland; Corresponding authors at: Trinity College Dublin, The University of Dublin, Department of Mechanical, Manufacturing & Biomedical Engineering, Dublin, Ireland (W. Zhang).
Silvia Marola: Politecnico di Milano, Department of Mechanical Engineering, Via la G. La Masa 1, 20156 Milano, Italy
Seán McConnell: 3CPT, Dublin, Ireland
Zhe Cai: Department of Materials, The University of Manchester, Manchester M13 9PL, UK
JanMell Dugenio: Trinity College Dublin, The University of Dublin, Department of Mechanical, Manufacturing & Biomedical Engineering, Dublin, Ireland
Ming Li: School of Mechanics, Civil Engineering and Architecture, Northwestern Polytechnical University, Xi’an 710072, PR China
William M. Abbott: Trinity College Dublin, The University of Dublin, Department of Mechanical, Manufacturing & Biomedical Engineering, Dublin, Ireland
Asli Coban: Trinity College Dublin, The University of Dublin, School of Chemistry, CRANN & AMBER, Dublin, Ireland
Arnoldas Sasnauskas: Trinity College Dublin, The University of Dublin, Department of Mechanical, Manufacturing & Biomedical Engineering, Dublin, Ireland
Shuo Yin: Trinity College Dublin, The University of Dublin, Department of Mechanical, Manufacturing & Biomedical Engineering, Dublin, Ireland
Ramesh Padamati Babu: Trinity College Dublin, The University of Dublin, School of Chemistry, CRANN & AMBER, Dublin, Ireland
Wajira Mirihanage: Department of Materials, The University of Manchester, Manchester M13 9PL, UK
Riccardo Casati: 3CPT, Dublin, Ireland
Rocco Lupoi: Trinity College Dublin, The University of Dublin, Department of Mechanical, Manufacturing & Biomedical Engineering, Dublin, Ireland; Corresponding authors at: Trinity College Dublin, The University of Dublin, Department of Mechanical, Manufacturing & Biomedical Engineering, Dublin, Ireland (W. Zhang).

Journal volume & issue: Vol. 245
p. 113301

Abstract

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A novel approach of Metal Additive Manufacturing using Powder Sheet (MAPS) is developed and demonstrated. A flexible metal particle-polymeric binder composite sheet is employed as innovative feedstock in this new method and this approach offers enhanced health and safety. MAPS successfully printed dense samples (99.99%). The chemical composition of the printed alloy resulted enriched in carbon compared to the feedstock powder due to the C pick-up during MAPS, leading to distinct microstructures and enhanced mechanical properties compared to those of laser beam powder bed fusion (PBF-LB/M) benchmark samples. In particular, the microstructural examinations of the MAPS samples show a coarser carbide network stable even after thermal treatment at high temperatures, while the tensile tests revealed that MAPS samples have a higher mechanical strength than the PBF-LB/M counterparts but possess lower ductility. The modification in the chemical composition indicates a strong potential for in-process alloying through MAPS. The demonstrated MAPS approach offers a novel avenue for manufacturing functional metal components with bespoke compositions and resulting properties.

Published in Materials & Design

ISSN: 0264-1275 (Print); 1873-4197 (Online)
Publisher: Elsevier
Country of publisher: United Kingdom
LCC subjects: Technology: Electrical engineering. Electronics. Nuclear engineering: Materials of engineering and construction. Mechanics of materials
Website: https://www.journals.elsevier.com/materials-and-design

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