In binder jet additive manufacturing (BJAM), uniformity and density of the powder layer impact green part quality. This study investigates the printability of unrefined sand using counter-roller spreading. Altair EDEM, a high-performance software powered by the Discrete Element Method (DEM), was used to simulate the BJAM process to evaluate powder bed homogeneity and density under various operating conditions, including roller rotational speed, traverse speed, powder layer thickness, and roller diameter. Utilizing high-performance computing (HPC) and graphics processing unit (GPU) clusters, time-efficient, and more realistic, simulations were performed simulating 300,000 grains. Detailed DEM simulations were executed by reconstructing representative particle shapes using two-dimensional images obtained using particle characterization equipment. The results highlight roller velocity and powder layer thickness as key determinants of sand spreadability. Optimal powder bed density (PBD) was achieved at a roller velocity of 20 mm/s with minimal deviation. A layer thickness exceeding 200 micrometers was found to prevent jamming and void formation, while percolation led to size segregation. The findings indicate that producing uniform and dense layers of unrefined sand is feasible but may incur trade-offs in print resolution and increased printing times. This work contributes to the advancement of sustainable and/or remote BJAM technologies, ensuring progress in both environmental sustainability and accessibility.
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DEM modeling of fine powder convection in a continuous vibrating bed reactor
Continuous vibrating spatial particle ALD reactors were developed to achieve high powder throughput while minimizing reactor footprint. Unlike fluidized bed reactors, continuous vibrating spatial particle ALD reactors operate below fluidization, using linear vibration to convey particles through alternating regions of precursor gas. Fine powder convection in these vibrating bed reactors is still not well understood, so cohesive discrete element- method (DEM) simulations were performed to investigate the solids flow behavior. Using a Fast Fourier Transform(FFT) algorithm, we constructed a sum-of-sines model for the reactor kinematics based on accelerometer data. Accelerometer results and DEM simulations revealed the role of high-frequency excitations and need for backsliding and sticking avoidance in horizontal conveyors at low-g accelerations. From these observations, we propose a novel sawtooth excitation to enable convection of cohesive fine powders at low flow velocities. The model results were compared to data from an in-house continuous vibrating spatial particle ALD reactor.
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- Award ID(s):
- 1852824
- PAR ID:
- 10231662
- Date Published:
- Journal Name:
- Powder technology
- Volume:
- 386
- ISSN:
- 0032-5910
- Page Range / eLocation ID:
- 209-220
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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