Material and process development for material extrusion metal additive manufacturing using recycled nickel

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.

Name thesis:degree_name

Master of Applied Science (MASc)

Discipline thesis:degree_discipline

Mechanical Engineering

Grantor

University of Ontario Institute of Technology

Year dc:date.issued

2024

Author dc:creator

• Karimi, Naeim

Advisor dc:contributor.advisor

• Fayazfar, Ramona

Language dc:language.iso

en

Handle dc:identifier.uri

https://hdl.handle.net/10155/2036

OAI identifier oai:identifier

oai:ontariotechu.scholaris.ca:10155/2036