3D Printing of "non-printable" high strength aluminium and magnesium alloys (PRINT4ALL)
2021-2022
The Friction Screw Extrusion Additive Manufacturing (FSEAM) process has been developed to enable the manufacturing of builds from high-strength aluminium and magnesium alloys. These alloys are often (too) difficult to print with common fusion-based approaches due to metallurgical problems leading to cracks, pores, preferred orientation and excessive residual stresses. The solid-state nature of FSEAM is an elegant way to avoid these problems.
The FSEAM process is based on a rotating, threaded tool that softens and transports the feedstock material to a build surface. Support edges at the printhead nozzle provide additional support during deposition.
First results with an Al-Mg-Si alloy (AA6060 T6) show a wide process window with deposition speeds up to 500 mm/min (maximum of setup) without pores or cracks and a strongly refined, equiaxed microstructure.
Proper selection of process parameters is important to obtain defect free builds. The PRINT4ALL project clearly showed the potential of the FSEAM process. Future research is aimed at a thorough understanding of the additive manufacturing process to broaden the range of alloys to be printed, extend the printing resolution down to the millimeter range and optimize the process and microstructural control enabling superior mechanical properties.
Funding
Financed through NWO-XS grant OCENW.XS21.1.078.
 Staff:
