
Use of thermomechanical analysis to determine viscosity for the simulation of the sintering process of binder jetted parts
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Metal Binder Jetting is a sinter-based additive manufacturing technology that produces a green part layer by layer in a powder bed using a liquid binder to consolidate powder particles. The resulting green part must undergo sintering to achieve its final mechanical and functional properties. However, sintering involves shrinkage and distortions, which are more pronounced in binder jetting compared to conventional processes. To predict and mitigate these deformations, models based on continuum mechanics, as introduced by Olevsky, exist and are implemented in commercially available software for stainless steel. However, the calibration of these material models requires extensive experimentation to determine shrinkage, viscosity, and grain growth, making the process time-consuming, especially since calibration must be repeated for each alloy, powder property, and thermal profile. Efficient determination of viscosity at elevated temperatures is crucial to unlocking the potential of sinter simulation. One method for viscosity determination involves beam bending tests to measure deflection rates at elevated temperatures across the sintering profile. These tests were performed in a sintering furnace, interrupting the process at various temperatures to analyze deflection. Concurrently, a thermomechanical analyzer (TMA) captured beam deflection throughout the temperature ramp. Stainless steel 316L and CoCrW were used in the experiments, sintered in argon and vacuum, respectively. Results indicated that TMA experiments are less time-consuming and yield more data points. Viscosity was calculated to be between 7∙10^8 and 4∙10^8 Pa∙s for oven experiments, while TMA results were an order of magnitude higher, aligning with findings by Borujeni et al. Understanding the differences between analytical equipment and oven environments is essential for accurate interpretation of results.