MMAE Seminar - Dr. Amir Mostafaei - Binder Jet 3D Printing - Process Parameters, Structure, Properties, and Challenges
Armour College of Engineering's Mechanical, Materials, and Aerospace Engineering Department will welcome Dr. Amir Mostafaei, a post-doctoral research fellow at the Manufacturing Futures Initiatives Center at Carnegie Mellon University, on Wednesday, July 10th, to present his lecture, Binder Jet 3D Printing - Process Parameters, Structure, Properties, and Challenges.
Abstract
As a non-beam-based additive manufacturing (AM) method, binder jet 3D printing (BJ3DP) is a process where a liquid binder is jetted on layers of powdered materials, selectively joined and then followed by densification process. Among AM technologies, binder jetting holds distinctive promise due to possibility of rapid production of complex structures to achieve isotropic properties in the 3D printed samples. By taking advantage of traditional powder metallurgy, BJ3DP machines can produce prototypes in which material properties and surface finish are similar to those attained with traditional powder metallurgy. Therefore, it is necessary to understand the physical processes during 3D printing and the fundamental science of densification after sintering and post heat treatment steps in order to correlated the microstructural evolution and properties of BJ3DP parts. Further, to determine the effects of the BJ3DP process on metallurgical properties, the role of powder characteristics (e.g. morphology, mean size, and distribution), printing process parameters (e.g. layer thickness, print orientation, binder saturation, print speed, and drying time), sintering (e.g. temperature and holding time) and post-processing are discussed. With the development of AM technologies and need for post-processing in BJ3DP parts, it is necessary to understand the microstructural evolution during densification process and here, processing steps are explained.
Biography
Amir Mostafaei is a post-doctoral research fellow at the Manufacturing Futures Initiatives (MFI) Center at Carnegie Mellon University since September 2018. He received his Ph.D. in Materials Science and Engineering from the University of Pittsburgh in August 2018, with the primary research focusing on binder jet 3D printing (BJ3DP) of structural, bio-compatible and magnetic shape memory alloys. Effects of print processing optimization during binder jetting as well as post-processing development including sintering and surface treatment of the 3D printed parts were investigated on the microstructural evolution, phase formation, and resulting properties of BJ3DP parts. Additionally, he has been working on laser powder bed fusion of metallic materials and evaluation of the processing parameters on the microstructure, porosity distribution, mechanical properties, and corrosion behavior of various additive manufactured parts from aluminum, stainless steel, and nickel-based alloys. He has published literature in high temperature corrosion and failure analysis of stainless steels and nickel-based superalloys used in petroleum and nuclear power plants, multi-functional organic coatings, welding metallurgy, and nano-materials fabrication. Finally, his research mainly focuses on applying fundamental aspects of materials science and engineering to address the demands of various manufacturing industries via additive manufacturing.