The primary purpose of using a laboratory heated press on IN 718 green bodies is to eliminate shaping defects inherent to the 3D printing process. By subjecting the printed part to uniform pressure and heat, this post-processing step closes microscopic gaps and delamination layers, significantly increasing the density of the object before it undergoes sintering.
Core Takeaway The printing process often leaves internal voids between material layers. Compacting the green body acts as a critical correction step, sealing these defects to ensure the final metal component achieves structural integrity and stable mechanical performance.
Addressing the Defects of Fused Filament Fabrication
The Challenge of Layered Printing
In Metal Fused Filament Fabrication (MFFF), the printer builds parts layer by layer. This often results in microscopic gaps or pores between the deposited paths.
The Risk of Delamination
Beyond simple gaps, the layers may not adhere perfectly to one another. This leads to delamination defects, where layers separate, creating structural weaknesses within the "green body" (the unsintered part).
The Mechanism of Warm-Pressure Consolidation
Applying Specific Parameters
To correct these defects, the green body is placed in a laboratory heated press. The process utilizes precise conditions, typically applying a temperature of 180 °C and a pressure of 92 MPa.
Inducing Binder Micro-Flow
The application of heat softens the polymer binder matrix within the green body. Simultaneously, the high pressure induces a "micro-flow," forcing the material to move and settle into the empty spaces.
Closing the Gaps
As the binder flows, it effectively seals the microscopic gaps and pores located between the printed paths. This mechanical compression physically forces the separated layers back together, repairing delamination issues.
The Impact on Final Part Quality
Improved Green Body Density
The immediate result of this compaction is a green body with significantly higher and more uniform density. The part becomes a solid, cohesive unit rather than a collection of loosely bonded layers.
Structural Integrity After Sintering
Because the green body is denser and free of internal voids, the final sintering process is more effective. This leads to a finished IN 718 component that exhibits superior structural integrity and reliable mechanical performance.
Understanding the Trade-offs
The Necessity of Precision
This process relies on exact parameters. Deviating from the specific temperature (180 °C) or pressure (92 MPa) can fail to induce the necessary flow or, conversely, distort the part's geometry.
Process Complexity
Adding a warm-pressing stage increases the complexity of the manufacturing workflow. It requires specialized equipment and adds time between printing and sintering, but the trade-off is often necessary for high-performance applications.
Making the Right Choice for Your Goal
To determine if this step is critical for your specific application, consider your performance requirements:
- If your primary focus is mechanical reliability: Use warm compaction to eliminate delamination, ensuring the part does not fail under stress.
- If your primary focus is part density: Use this process to minimize porosity, which is essential for achieving near-fully dense final metal parts.
By integrating this consolidation step, you transform a potentially porous print into a robust, high-performance engineering component.
Summary Table:
| Feature | Specification/Detail |
|---|---|
| Target Material | IN 718 (Nickel-based Superalloy) |
| Processing Temperature | 180 °C |
| Applied Pressure | 92 MPa |
| Primary Goal | Eliminate microscopic gaps and delamination |
| Mechanism | Induced binder micro-flow |
| Outcome | Higher green body density & structural integrity |
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References
- Yvonne Thompson, Peter Felfer. Metal fused filament fabrication of the nickel-base superalloy IN 718. DOI: 10.1007/s10853-022-06937-y
This article is also based on technical information from Kintek Press Knowledge Base .
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