Production, process and properties of 3d printed multi-metal parts

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isbn9789526421766.pdf (4.1 MB)

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School of Engineering | Doctoral thesis (article-based) | Defence date: 2024-12-18
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Authors

Date

2024

Department

Energia- ja konetekniikan laitos
Department of Energy and Mechanical Engineering

Major/Subject

Mcode

Degree programme

Language

en

Pages

72 + app. 32

Series

Aalto University publication series DOCTORAL THESES, 267/2024

Abstract

Additive manufacturing (AM), also known as 3D printing, is an advanced technology that enables the fabrication of multi-material parts with intricate internal structures and lightweight lattice designs. Compared to conventional manufacturing methods, AM offers opportunities for engineering optimization and performance enhancements. Its material efficiency minimizes waste and usage, aligning with sustainability goals and economic considerations. Particularly, multi-metal parts additive manufacturing (MMAM) represents a transformative approach that integrates multiple metals within a single component, leading to superior material properties, structural complexity, and functional optimization. Despite its promising potential, multi-metal AM faces several limitations and challenges. Key issues include maintaining metallurgical compatibility between dissimilar metals, controlling thermal stresses and distortions during the process, achieving high-quality interfaces between different materials, and high production costs associated with some specific AM technologies. Additionally, the development of reliable process parameters, effective post-processing techniques, and robust quality control methods remains critical for the widespread adoption of multi-metal AM. Addressing these challenges is essential to unlock the full potential of multi-metal additive manufacturing and expand its applications across various industries, including aerospace, automotive, and biomedical engineering. This dissertation explores the feasibility of utilizing cost-effective additive manufacturing (AM) technologies to produce multi-metal parts. The study evaluates the properties, challenges, and limitations associated with this manufacturing approach, providing valuable insights into its potential applications and advancements in the field of multi-metal AM. Additionally, the interface between the two metals is specifically characterized in terms of their microstructural features, including porosity, intermetallic compound formation, and hardness mismatch. The dissertation employs material extrusion (MEX) and vat photopolymerization (VPP) additive manufacturing methods, known for their high availability and cost-effectiveness. These desktop printers are widely utilized in engineering, product design, dentistry, and other fields requiring high-resolution, intricate 3D printed parts. However, multi-metal parts produced using MEX and VPP technologies often exhibit poor mechanical properties inherent to sintered parts, primarily due to high levels of porosity. The de-binding process results in the formation of voids among the metal particles, making it challenging to diminish these voids during the sintering process, even with elevated temperatures and prolonged durations.

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Supervising professor

Salmi, Mika, Asst. Prof., Aalto University, Department of Energy and Mechanical Engineering, Finland

Thesis advisor

Partanen, Jouni, Prof., Aalto University, Department of Energy and Mechanical Engineering, Finland

Keywords

additive manufacturing, multi-metal parts, material extrusion, metal vat photopolymerization, alloying

Other note

Parts

  • [Publication 1]: Mousapour, M., Salmi, M., Klemettinen, L., & Partanen, J. 2021. Feasibility study of producing multi-metal parts by Fused Filament Fabrication (FFF) technique. Journal of Manufacturing Processes, 67, 438-446. JUFO level 1.
    Full text in Acris/Aaltodoc: https://urn.fi/URN:NBN:fi:aalto-202107017851
    DOI: 10.1016/j.jmapro.2021.05.021 View at publisher
  • [Publication 2]: Mousapour, M., Partanen, J., & Salmi, M., 2023. NiTiCu alloy from elemental and alloyed powders using vat photopolymerization additive manufacturing. Additive Manufacturing, 78, 103853. JUFO level 3.
    Full text in Acris/Aaltodoc: https://urn.fi/URN:NBN:fi:aalto-202311156862
    DOI: 10.1016/j.addma.2023.103853 View at publisher
  • [Publication 3]: Mousapour, M., Kumar, SS., Partanen, J., & Salmi, M., 2025. 3d printing of a continuous carbon fiber reinforced bronze-matrix composite using material extrusion. Composites Part B: Engineering, 289, 111961. JUFO level 3.
    Full text in Acris/Aaltodoc: https://urn.fi/URN:NBN:fi:aalto-202411217435
    DOI: 10.1016/j.compositesb.2024.111961 View at publisher

Citation

Permanent link to this item

https://urn.fi/URN:ISBN:978-952-64-2176-6

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[diss] Insinööritieteiden korkeakoulu / ENG