Scholarlink

<p>Material extrusion (MEX) of metals, achieved by incorporating high metal contents into a polymer binder followed by debinding and sintering, offers a cost-effective and energy-efficient alternative to powder bed fusion. This study demonstrates, for the first time, the use of spiky nickel powders in MEX to fabricate nickel components with ~ 88% relative density after debinding and sintering. Nickel’s corrosion and high-temperature resistance make it ideal for demanding applications in chemical processing, heat exchangers, and aerospace. We investigated the influence of powder morphology and maximum packing load on feedstock formulation and confirmed filament extrudability through rheological analysis and experimental validation. Solvent debinding generated interconnected pores for binder removal, while sintering at 1100&#xa0;°C produced an 18% increase in tensile strength compared to 1000&#xa0;°C. Spiky powders limited the maximum powder loading to 38 vol%; nevertheless, the optimized debinding–sintering route produced components with ~ 88% relative density.</p> Graphical abstract <p></p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Nickel material extrusion additive manufacturing with spiky carbonyl powder: Feedstock development, debinding, and sintering

  • 期刊论文

  • 发表日期：

    2026年3月6日

查看全文
  • Naeim Karimi,
  • Hatem Zurob,
  • Ramona Haniyeh Fayazfar,
  • Ankit Sahai,
  • Rahul Swarup Sharma

摘要

Material extrusion (MEX) of metals, achieved by incorporating high metal contents into a polymer binder followed by debinding and sintering, offers a cost-effective and energy-efficient alternative to powder bed fusion. This study demonstrates, for the first time, the use of spiky nickel powders in MEX to fabricate nickel components with ~ 88% relative density after debinding and sintering. Nickel’s corrosion and high-temperature resistance make it ideal for demanding applications in chemical processing, heat exchangers, and aerospace. We investigated the influence of powder morphology and maximum packing load on feedstock formulation and confirmed filament extrudability through rheological analysis and experimental validation. Solvent debinding generated interconnected pores for binder removal, while sintering at 1100 °C produced an 18% increase in tensile strength compared to 1000 °C. Spiky powders limited the maximum powder loading to 38 vol%; nevertheless, the optimized debinding–sintering route produced components with ~ 88% relative density.

Graphical abstract