Process for Co-sintering Additive Manufacturing Parts

FABRICATED GREEN HEAT EXCHANGER PLATES BY SEAM PROCESS SINTERED STACKED HEAT EXCHANGER ASSEMBLY

Executive Summary

Metal additive manufacturing is an attractive process for producing highly complex and tailored components from superalloys for high temperature applications. However, the processes can be slow and are not scaleable for large volume production. Researchers at Michigan State University have recently developed an efficient additive manufacturing process for metal parts that is scalable, low cost and creates parts with very high relative densities with no geometrical distortion. The process can be also used to make complex structures with enclosed channels.

Description of the Technology

The technology is based on an additive manufacturing process using UV light curing of mixture composed of a photopolymer and metal powders. This process termed SEAM (scalable and expeditious additive manufacturing) involves a curing mechanism and co-debinding and co-sintering of multiple parts. Experiments have been conducted using a Haynes 214, Nickel based superalloy to manufacture parts for a high temperature super critical CO₂ heat exchanger.

Benefits

Scalable manufacturing process allows multiple parts to be formed at the same time
Design simplicity
Cost effective process reduces manufacturing time
Allows production of parts with enclosed channels and complex internal structures
Can co-debind and co-sinter multiple green parts together in a single heating cycle
High part density achieved up to 99.5% relative density with no geometrical distortion
Homogenous microstructure parts with low residual stress which does not need any additional heating cycles
Superior surface roughness compared to laser sintered process

Applications

Parts for high temperature applications including engine turbine blades, nuclear reactors, turbochargers, heat exchangers
Automotive parts
Medical / Dental parts and devices
End of arm tooling
Jewelry

Patent Status