Quality over Quantity: How Different Dispersion Qualities of Minute Amounts of Nano-Additives Affect Material Properties in Powder Bed Fusion of Polyamide 12

The great interest, within the fields of research and industry, in enhancing the range and functionality of polymer powders for laser powder bed fusion (LB-PBF-P) increases the need for material modifications. To exploit the full potential of the additivation method of feedstock powders with nanoparticles, the influence of nanoparticles on the LB-PBF process and the material behavior must be understood. In this study, the impact of the quantity and dispersion quality of carbon nanoparticles deposited on polyamide 12 particles is investigated using tensile and cubic specimens manufactured under the same process conditions. The nano-additives are added through dry coating and colloidal deposition. The specimens are analyzed by tensile testing, differential scanning calorimetry, polarized light and electron microscopy, X-ray diffraction, infrared spectroscopy, and micro-computed tomography. The results show that minute amounts (0.005 vol%) of highly dispersed carbon nanoparticles shift the mechanical properties to higher ductility at the expense of tensile strength. Despite changes in crystallinity due to nano-additives, the crystalline phases of polyamide 12 are retained. Layer bonding and part densities strongly depend on the quantity and dispersion quality of the nanoparticles. Nanoparticle loadings for CO2 laser-operated PBF show only minor changes in material properties, while the potential is greater at lower laser wavelengths

Influence of sub-monolayer quantities of carbon nanoparticles on the melting and crystallization behavior of polyamide 12 powders for additive manufacturing

In this paper, the influence of 0.005 vol% and 0.05 vol% of carbon nanoparticles on the surface of polyamide 12 powder particles by dry coating and colloidal additivation is evaluated in great detail concerning thermal and microstructural properties. The dispersion of the nanoparticles on the polymer surface influences the flowability of the feedstock powder already during the additivation process. When analyzing the composite powders dynamically and isothermally with fast scanning and differential scanning calorimetry, carbon nanoparticles influence the crystallization behavior of the feedstock material significantly by acting as nucleation seeds, already at a few percent of a monolayer coating, while showing no effect on the fast heating process. The difference in calorimetric properties and crystallization behavior between the additivation methods of different abrasive forces is discussed. The surface-additivated carbon nanoparticles significantly increase the crystalline area by up to a threefold and the crystallization rate by up to a hundredfold. Furthermore, they change the crystal growth from a typical two- to three-dimensional growth of spherulites to a one- to two-dimensional growth of ellipsoidal impinged lamellar structures. Between 0.005 vol% and 0.05 vol% of well-dispersed carbon nanoparticles should be added to polyamide 12 to trigger an anisotropic heterogeneous nucleation while avoiding agglomerates

Improved process efficiency in laser-based powder bed fusion of nanoparticle coated maraging tool steel powder

Research and development in the field of metal-based additive manufacturing are advancing steadily every year. In order to increase the efficiency of powder bed fusion of metals using a laser beam system (PBF LB/M), machine manufacturers have implemented extensive optimizations with regard to the laser systems and build volumes. However, the optimization of metallic powder materials using nanoparticle additives enables an additional improvement of the laser–material interaction. In this work, tool steel 1.2709 powder was coated with silicon carbide (SiC), few-layer graphene (FLG), and iron oxide black (IOB) on a nanometer scale. Subsequently, the feedstock material and the modified powder materials were analyzed concerning the reflectance of the laser radiation and processed by PBF-LB/M in a systematic and consistent procedure to evaluate the impact of the nano-additivation on the process efficiency and mechanical properties. As a result, an increased build rate is achieved, exhibiting a relative density of 99.9% for FLG/1.2709 due to a decreased reflectance of this modified powder material. Furthermore, FLG/1.2709 provides hardness values after precipitation hardening with only aging comparable to the original 1.2709 material and is higher than the SiC- and IOB-coated material. Additionally, the IOB coating tends to promote oxide-formation and lack-of-fusion defects