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Casting Protocols for the Production of Open Cell Aluminum Foams by the Replication Technique and the Effect on Porosity

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Influence of Salt Support Structures on Material Jetted Aluminum Parts.

Benedikt Kirchebner¹, Maximilian Ploetz¹, Christoph Rehekampff²

¹Chair of Metal Forming and Casting, Technical University of Munich, Walther-Meissner-Strasse 4, 85748 Garching, Germany.

Materials (Basel, Switzerland)

|August 7, 2021

Summary

Using water-soluble salt supports in metal material jetting can reduce costs. This study found salt supports do not negatively impact aluminum part quality, but do increase dendrite arm spacing.

Keywords:

additive manufacturing material jetting support structure

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Area of Science:

Additive Manufacturing
Materials Science
Metallurgy

Background:

Material jetting processes for metals require support structures, increasing post-processing time and cost.
Water-soluble salt supports offer a potential solution for faster, more economical support removal.

Purpose of the Study:

To investigate the influence of molten salt support structures on material jetted aluminum parts.
To assess potential issues like corrosion, remelting, and microstructural changes.

Main Methods:

Analysis of three sample geometries using optical microscopy, confocal laser scanning microscopy, energy-dispersive X-ray spectroscopy, and micro-hardness testing.
Evaluation of the interaction between molten salt supports and jetted aluminum.

Main Results:

No significant influence observed on aluminum part remelting, micro-hardness, or chemical reactions.
A notable increase in dendrite arm spacing was observed in aluminum printed on salt supports.

Conclusions:

Molten salt supports are viable for material jetting of aluminum without detrimental effects on key material properties.
The increased dendrite arm spacing suggests a modification of the aluminum's microstructure due to thermal effects from the salt support.