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

  • Patent pending

 

Licensing Rights

Full licensing rights available

 

References

“From Photopolymerization of Metal Suspension to Practical and Economical Additive Manufacturing of Haynes 214 Alloy for High Temperature Application”, International Additive Manufacturing Conference IAM2022, 10/19/22

 

Inventors

Dr. Haseung Chung, Dr. Patrick Kwon

 

TECH ID

TEC2023-0017

Patent Information:

Category(s):

For Information, Contact:

Jon Debling
Technology Manager
Michigan State University
deblingj@msu.edu
Keywords: