A comparatively new approach for the manufacturing of metal parts is the use of fused deposition modeling (FDM). Here, a metal powder filled filament is processed to manufacture components (green part). The subsequent process chain is identical to that of metal injection molding (MIM). Thus, the polymer binder is initially removed from the component (brown part). The metal particles are finally sintered in a furnace to form a pure metal component (white part/final part). The aim of this study is the investigation of the FDM process for the fabrication of metal components with regard to process parameters. This includes the consideration of material-specific parameters influencing the extrusion process. Especially, the material temperature and material behavior within the FDM nozzle are analyzed. On this basis, the mechanical properties of specimens manufactured with different nozzle sizes and strand geometries are examined. The resulting properties are used to evaluate the suitability of the specific strand-nozzle combination for processing the metal-polymer composite. In particular, the density of the components and the process reliability are important evaluation criteria. Finally, the comparison of white parts with parts manufactured in selective laser melting (SLM) shows the possibilities offered by processing metal-polymer composites in FDM.

中文翻译：

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通过熔融沉积建模制造的金属聚合物复合材料的工艺参数研究

一种相对较新的金属零件制造方法是使用熔融沉积建模 (FDM)。在这里，金属粉末填充的灯丝被加工以制造组件（生坯）。后续工艺链与金属注射成型 (MIM) 相同。因此，聚合物粘合剂最初从组件（棕色部分）中去除。金属颗粒最终在炉中烧结以形成纯金属部件（白色部分/最终部分）。本研究的目的是研究 FDM 工艺制造金属部件的工艺参数。这包括考虑影响挤出过程的材料特定参数。特别是，分析了 FDM 喷嘴内的材料温度和材料行为。在此基础上，检查了用不同喷嘴尺寸和绞线几何形状制造的试样的机械性能。所得特性用于评估特定线束喷嘴组合在加工金属聚合物复合材料时的适用性。尤其是部件的密度和工艺可靠性是重要的评价标准。最后，白色零件与选择性激光熔化 (SLM) 制造零件的比较显示了在 FDM 中加工金属聚合物复合材料的可能性。组件的密度和工艺可靠性是重要的评估标准。最后，白色零件与选择性激光熔化 (SLM) 制造零件的比较显示了在 FDM 中加工金属聚合物复合材料的可能性。组件的密度和工艺可靠性是重要的评估标准。最后，白色零件与选择性激光熔化 (SLM) 制造零件的比较显示了在 FDM 中加工金属聚合物复合材料的可能性。