Use of aqueous polyvinyl alcohol in binder jetting of Inconel 718

Abstract

Binders used in binder jetting often pose health and environmental risks during processing and post processing operations. The print-heads which are used to deposit binder selectively on the feedstock are prone to clogging, despite the trend of print-heads being highly customised to suit different kinds of binders. These factors often hide the advantages of binder jetting as an additive manufacturing process, especially its scalability and its faster printing rates in comparison to powder bed fusion methods. The work presented here takes a step back and focuses on the development of an aqueous, polyvinyl alcohol (PVA)-based liquid binder that is easy to manufacture and store, safe to handle, and can be reliably jetted to print parts. The feedstock considered was Inconel 718, a nickel-based super alloy which can be effectively processed by binder jetting without niobium segregation. PVA was added to the Inconel 718 powder in dry, granular form to manufacture a modified feedstock. The study also investigated the role of molecular weight of the PVA used, sintering environments and post-processing methods like hot isostatic pressing (HIP) on process responses like part densification, tensile strength, and hardness. Three different types of PVA were chosen which had molecular weights 10,000 g/mol (low molecular weight or LMW), 26,000 g/mol (medium molecular weight or MMW), and 84,000 g/mol (high molecular weight or HMW). The compatibility of the liquid, aqueous PVA-based binders with virgin Inconel 718 was examined by measuring the contact angle. The liquid, aqueous binder having MMW PVA reported better wetting with the Inconel 718 powder with a wetting angle of 26.6 which was lower than the wetting angle of 42.4°, seen in case of a commercial resin-based binder. The green strength reported by the MMW PVA liquid binder was 220 kPa which was higher than the other two PVA-based liquid binders. Green parts, upon successful printing, were sintered at 1260 °C. It was observed that a part printed using MMW PVA had a densification of 96.16% when sintered in 99.98% by volume argon gas, which increased to 98.96% after undergoing HIP. The same part reported a densification of 88.69% when sintered in a 95% by volume N2 and 5% by volume H2 gaseous environment, which was later attributed to the uptake of nitrogen by the chromium present in Inconel 718, which prevented necking between particles. Tensile specimens printed using MMW PVA, sintered in a 99.98% argon environment, showed the highest ultimate tensile strength of 220 MPa, which increased to 1010 MPa after the HIP process, which can be compared to commercially available Inconel 718.