Challenges And Current State Of Sinter-Based AM Of Oxygen-Affine Lightweight Metal Alloys Using The Slurry-Based Gel Casting Process

There is an increasing interest in the additive manufacturing (AM) production of light metal alloys such as titanium or aluminum alloys. Due to their good mechanical performance combined with low density, these alloys are in high demand in various industries, such as in the mobility sector. Compared to powder bed AM processes, slurry-based processes have the advantage that no dry, potentially flammable powder has to be handled. Furthermore, even irregular powder with poor flowability can be processed into homogeneously packed green parts. However, challenges arise in connection with reactive powders that are oxygen-affine: Potential reactions between the powder and the suspension medium, as well as the complete removal of the organic components during thermal debinding, pose challenges. This paper evaluates the production of Ti-6Al-4V and Al6061 sinter parts using the gel casting process and presents results regarding the material properties achieved and the current state of development.