Multi-Material Additive Manufacturing: Creating IN718-AISI 316L Bimetallic Parts by 3D Printing, Debinding, and Sintering

Paolo Ferro (), Alberto Fabrizi, Hamada Elsayed and Gianpaolo Savio ()
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Paolo Ferro: Department of Engineering and Management, University of Padova, 36100 Vicenza, Italy
Alberto Fabrizi: Department of Engineering and Management, University of Padova, 36100 Vicenza, Italy
Hamada Elsayed: Department of Industrial Engineering, University of Padova, 35131 Padua, Italy
Gianpaolo Savio: Department of Civil, Environmental and Architectural Engineering, University of Padova, 35131 Padua, Italy

Sustainability, 2023, vol. 15, issue 15, 1-19

Abstract: Allowing for complex shape and low energy consumption, 3D printing, debinding, and sintering (PDS) is a promising and cost-effective additive manufacturing (AM) technology. Moreover, PDS is particularly suitable for producing bimetallic parts using two metal/polymer composite filaments in the same nozzle, known as co-extrusion, or in different nozzles, in a setup called bi-extrusion. The paper describes a first attempt to produce bimetallic parts using Inconel 718 and AISI 316L stainless steel via PDS. The primary goal is to assess the metallurgical characteristics, part shrinkage, relative density, and the interdiffusion phenomenon occurring at the interface of the two alloys. A first set of experiments was conducted to investigate the effect of deposition patterns on the above-mentioned features while keeping the same binding and sintering heat treatment. Different sintering temperatures (1260 °C, 1300 °C, and 1350 °C) and holding times (4 h and 8 h) were then investigated to improve the density of the printed parts. Co-extruded parts showed a better dimensional stability against the variations induced by the binding and sintering heat treatment, compared to bi-extruded samples. In co-extruded parts, shrinkage depends on scanning strategy; moreover, the higher the temperature and holding time of the sintering heat treatment, the higher the density reached. The work expands the knowledge of PDS for metallic multi-materials, opening new possibilities for designing and utilizing functionally graded materials in optimized components. With the ability to create intricate geometries and lightweight structures, PDS enables energy savings across industries, such as the aerospace and automotive industries, by reducing component weight and enhancing fuel efficiency. Furthermore, PDS offers substantial advantages in terms of resource efficiency, waste reduction, and energy consumption compared to other metal AM technologies, thereby reducing environmental impact.

Keywords: additive manufacturing; debinding; sintering; Inconel 718; AISI 316L SS; bimetal; microstructure; interdiffusion; functionally graded materials; co-extrusion (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2023
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