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Manufacturing of Nickel Based Superalloys Composites Using a Novel Binder Jetting Additive Manufacturing Process

Fadavi Boostani, Alireza (2023) Manufacturing of Nickel Based Superalloys Composites Using a Novel Binder Jetting Additive Manufacturing Process. Master's Thesis, University of Pittsburgh. (Unpublished)

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Enhancing the density of additively manufactured parts produced using a powder-based process is challenging. This usually limits the use of additive manufacturing (AM) for different applications. In this study, we demonstrated the promising effects of graphene sheets as densifier agents for biner jet printing of alloy 625 powders. This enables more efficient and economical use of the industries to utilize water atomized powder compared to gas atomized powders. We assess the environmentally friendly approach called “graphene encapsulating” for in-situ production of graphene sheets during the ball milling process. This method works based on the intrinsic shearing capability of SiC nanoparticles to peel off graphene sheets from the graphite during ball milling process. Aggregates mixed with water-atomized alloy 625 powders were then fed them into the Ex-one binder jet additive machine to print the samples. The results were compared with samples printed mainly with gas- and water-atomized powders without graphene.
This significant impact of the graphene encapsulating process on diminishing the agglomeration of nanoparticles as a crucial problem in fabrication of metal and polymer matrix nanocomposites was demonstrated. The use of graphene nullified the agglomeration propensity of nanoparticulates during the liquid phase sintering process. Results showed an exceptional sponge morphology of graphene sheets to activate capillary forces, stimulating circulation of liquid metals containing nanoparticles and thereby enhancing sintering density.


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Item Type: University of Pittsburgh ETD
Status: Unpublished
CreatorsEmailPitt UsernameORCID
Fadavi Boostani, Alireza
ETD Committee:
TitleMemberEmail AddressPitt UsernameORCID
Thesis AdvisorChmielus,
Committee MemberNettleship,
Committee MemberGleeson,
Date: 19 January 2023
Date Type: Publication
Defense Date: 7 July 2022
Approval Date: 19 January 2023
Submission Date: 14 November 2022
Access Restriction: 2 year -- Restrict access to University of Pittsburgh for a period of 2 years.
Number of Pages: 116
Institution: University of Pittsburgh
Schools and Programs: Swanson School of Engineering > Mechanical Engineering and Materials Science
Degree: MS - Master of Science
Thesis Type: Master's Thesis
Refereed: Yes
Uncontrolled Keywords: Binder Jetting Additive Manufacturing, SiC particles
Date Deposited: 19 Jan 2023 19:25
Last Modified: 19 Jan 2023 19:25


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