{"id":{"repo_id":"uoit","oai_identifier":"oai:ontariotechu.scholaris.ca:10155/2036"},"canonical_url":"https://search.dev.ndltd.org/etd/uoit/oai:ontariotechu.scholaris.ca:10155/2036","repository":{"repo_id":"uoit","name":"Ontario Institute of Technology","base_url":"https://ontariotechu.scholaris.ca/server/oai/request"},"display":{"title":"Material and process development for material extrusion metal additive manufacturing using recycled nickel","abstract":"Metal Extrusion 3D-printing is a cost-effective alternative to powder bed fusion for producing metal parts, but limited material compatibility with this technique and reliance on virgin resources hinder wider adoption and raise sustainability concerns due to the depletion of natural resources. This research pioneers the use of recycled nickel powders to develop innovative feedstock/filaments for material-extrusion 3D-printing of dense nickel components, marking the first study of its kind. This research investigates the impact of morphology of recycled powder and maximum packing load on feedstock preparation, 3D printing, and subsequent sintering. Using spiky-shaped nickel powder, the maximum volume-fraction required to produce dense parts was 38 vol%, which is more efficient than spherical powder that requires over 50 vol% to achieve successful sintering. 3D-printing, debinding, and sintering were evaluated and optimized using rheology, thermal, and microstructural analysis leading to the production of parts with 91% relative density and 340 MPa tensile strength.","abstract_html":"Metal Extrusion 3D-printing is a cost-effective alternative to powder bed fusion for producing metal parts, but limited material compatibility with this technique and reliance on virgin resources hinder wider adoption and raise sustainability concerns due to the depletion of natural resources. This research pioneers the use of recycled nickel powders to develop innovative feedstock/filaments for material-extrusion 3D-printing of dense nickel components, marking the first study of its kind. This research investigates the impact of morphology of recycled powder and maximum packing load on feedstock preparation, 3D printing, and subsequent sintering. Using spiky-shaped nickel powder, the maximum volume-fraction required to produce dense parts was 38 vol%, which is more efficient than spherical powder that requires over 50 vol% to achieve successful sintering. 3D-printing, debinding, and sintering were evaluated and optimized using rheology, thermal, and microstructural analysis leading to the production of parts with 91% relative density and 340 MPa tensile strength.","abstract_has_math":false,"creators":["Karimi, Naeim"],"institution":"University of Ontario Institute of Technology","degree_name":"Master of Applied Science (MASc)","degree_level":null,"degree_discipline":"Mechanical Engineering","degree_department":null,"school":null,"contributors":[],"advisors":["Fayazfar, Ramona"],"committee_chairs":[],"committee_members":[],"year":2024,"date_issued":"2024-08-01","date_published":"2024-08-01","updated_at":"2026-07-24T05:35:22Z","subjects":[],"languages":["en"],"rights":[],"rights_urls":[],"identifier_entries":[]},"links":{"outbound_url":"https://hdl.handle.net/10155/2036","outbound_label":"Handle","outbound_source":"dc:identifier.uri"},"metadata_groups":[{"id":"people","label":"People","entries":[{"key":"dc:contributor.advisor","label":"Advisor","values":["Fayazfar, Ramona"]},{"key":"dc:creator","label":"Author","values":["Karimi, Naeim"]}]},{"id":"academic_context","label":"Academic Context","entries":[{"key":"dc:date.accessioned","label":"Dc Date Accessioned","values":["2026-01-19T20:59:05Z"]},{"key":"dc:date.issued","label":"Date","values":["2024-08-01"]},{"key":"dc:type","label":"Dc Type","values":["Thesis"]},{"key":"thesis:degree_discipline","label":"Discipline","values":["Mechanical Engineering"]},{"key":"thesis:degree_name","label":"Degree Name","values":["Master of Applied Science (MASc)"]},{"key":"thesis:institution_name","label":"Thesis Institution Name","values":["University of Ontario Institute of Technology"]}]},{"id":"language_rights","label":"Language and Rights","entries":[{"key":"dc:language.iso","label":"Language (ISO)","values":["en"]}]},{"id":"identifiers","label":"Identifiers","entries":[{"key":"dc:identifier.uri","label":"Identifier URI","values":["https://hdl.handle.net/10155/2036"]}]},{"id":"additional","label":"Additional Metadata","entries":[{"key":"dc:description.abstract","label":"Abstract","values":["Metal Extrusion 3D-printing is a cost-effective alternative to powder bed fusion for producing metal parts, but limited material compatibility with this technique and reliance on virgin resources hinder wider adoption and raise sustainability concerns due to the depletion of natural resources. This research pioneers the use of recycled nickel powders to develop innovative feedstock/filaments for material-extrusion 3D-printing of dense nickel components, marking the first study of its kind. This research investigates the impact of morphology of recycled powder and maximum packing load on feedstock preparation, 3D printing, and subsequent sintering. Using spiky-shaped nickel powder, the maximum volume-fraction required to produce dense parts was 38 vol%, which is more efficient than spherical powder that requires over 50 vol% to achieve successful sintering. 3D-printing, debinding, and sintering were evaluated and optimized using rheology, thermal, and microstructural analysis leading to the production of parts with 91% relative density and 340 MPa tensile strength."]},{"key":"dc:title","label":"Title","values":["Material and process development for material extrusion metal additive manufacturing using recycled nickel"]}]}],"canonical_facts":{"dc:contributor.advisor":["Fayazfar, Ramona"],"dc:creator":["Karimi, Naeim"],"dc:date.accessioned":["2026-01-19T20:59:05Z"],"dc:date.issued":["2024-08-01"],"dc:description.abstract":["Metal Extrusion 3D-printing is a cost-effective alternative to powder bed fusion for producing metal parts, but limited material compatibility with this technique and reliance on virgin resources hinder wider adoption and raise sustainability concerns due to the depletion of natural resources. This research pioneers the use of recycled nickel powders to develop innovative feedstock/filaments for material-extrusion 3D-printing of dense nickel components, marking the first study of its kind. This research investigates the impact of morphology of recycled powder and maximum packing load on feedstock preparation, 3D printing, and subsequent sintering. Using spiky-shaped nickel powder, the maximum volume-fraction required to produce dense parts was 38 vol%, which is more efficient than spherical powder that requires over 50 vol% to achieve successful sintering. 3D-printing, debinding, and sintering were evaluated and optimized using rheology, thermal, and microstructural analysis leading to the production of parts with 91% relative density and 340 MPa tensile strength."],"dc:identifier.uri":["https://hdl.handle.net/10155/2036"],"dc:language.iso":["en"],"dc:title":["Material and process development for material extrusion metal additive manufacturing using recycled nickel"],"dc:type":["Thesis"],"thesis:degree_discipline":["Mechanical Engineering"],"thesis:degree_name":["Master of Applied Science (MASc)"],"thesis:institution_name":["University of Ontario Institute of Technology"]},"updated_at":"2026-07-24T05:35:22Z"}