Mitigation of gravity-induced distortions of binder-jetting components during rotational sintering

Using theory and simulations, the challenge of gravity-induced distortions during sintering is addressed and a mitigation strategy is proposed. Based on the continuum theory of sintering, the finite element simulation demonstrates the advantages of a rotating furnace to counteract gravity forces during sintering. Its application for stainless steel hollow parts produced by additive manufacturing (binder jetting) is demonstrated, numerically, for reliable industrial production of complex shapes. Sintering a tube in a very slow rotating motion exhibits an improvement in the final deformation ratio compared to a conventional sintering process. The same concept has been adapted for higher furnace revolution speeds and the centrifugal force is now surpassing the effects of gravity. An extended study of sintering under microgravity for space-borne applications is also widely depicted with the same model. Indeed, it shows the possibility of reproducing Earth's sintering conditions at places where gravity is insufficient to provide acceptable densification and shape conservation during sintering.