The most popular techniques for additive manufacturing (AM) of metals (e.g.
powder bed fusion or directed energy deposition) utilize high-energy beams
(e.g. lasers or electron beams) to directly fuse metal powders into bulk
components. However, while these processes are promising for specific forms of
production, they can be relatively expensive and energy-intensive. Furthermore,
these processes result in complex thermal histories, which can produce large
residual stresses along with difficult to predict and anisotropic
microstructures and mechanical properties. As an alternative, a suite of
non-fusion AM processes have been developed or are under development for the
production of metal and ceramic components. In general, these processes use AM
to produce “green” parts that are subsequently consolidated into bulk
components using powder consolidation techniques, such as debinding and
sintering. The most popular technique is binder jetting, during which a liquid
binder is selectively deposited on a powder bed via inkjet printheads. Similar
to powder injection molding, metal or ceramic powder can also be mixed with a
polymer blend to produce pellets or filament that are formed into green parts
via extrusion AM (e.g. fused filament fabrication). Additionally, powder can be
mixed with a photopolymer resin to produce green parts via AM
photopolymerization processes (e.g. stereolithography). Other techniques for
producing green parts via AM exist. Such processes address the high capital and
operating costs along with the residual stresses and microstructural concerns
of fusion-based AM. Additionally, these processes could enable the development
of mobile machines for in-field production of metal and ceramic components.
Example topics for this symposium include, but are not limited to,
binder/polymer/resin development, AM process design/modification/optimization,
debinding, sintering, and characterization of both green parts and bulk
components. Furthermore, presentations on both modeling and experimental
efforts are encouraged.
This symposium will cover recent advances in the powder-route synthesis of bulk
nanostructured materials and nanocomposites. Talks are welcome on all aspects
of the powder processing of nanostructured materials. Topics of special
interest include the following:
(1) powder synthesis methods: mechanical alloying and milling, rapid
solidification, chemistry-based techniques, emerging powder synthesis methods
(2) advanced powder forming methods: novel pressing techniques, binder jet
3Dprinting, laser/electron beam/plasma powder deposition processes, injection
molding;
(3) pressure-assisted consolidation techniques: spark plasma sintering, cold
spray deposition, hot pressing, shock-wave consolidation;
(4) pressureless densification techniques: liquid phase sintering, liquid metal
infiltration, nanophase separation sintering, microwave sintering;
(5) new and emerging powder metallurgy-based consolidation processes.
We strongly encourage talks on structural evolution during these synthesis,
forming, and densification operations.
In this proposed six-session symposium, papers addressing all aspects of powder
metallurgy of light, reactive and other non-ferrous metals and their
applications will be welcome. The following topics of the powder metallurgy of
light, reactive and other non-ferrous metals are particularly welcome: (i)
novel synthesis of powder materials; (ii) production and characterisation of
spherical powders for additive manufacturing (AM) or 3D printing, (iii) new
developments and understanding of powder consolidation (e.g. spark plasma
sintering; microwave sintering; forging, extrusion, powder injection moulding,
cold spray forming); (iv) additive manufacturing or 3D printing; (v)
functionally graded materials and novel metal-ceramic or metal-polymer
composites; (vi) novel applications of powder materials including loose
powders, porous structures and fully consolidated products; (vii) advances in
characterization of powder materials; and (viii) modelling and simulation of
all aspects of the powder metallurgy of light, reactive and other non-ferrous
metals.