Rheological Characterization of Room Temperature Powder Metal Paste for Extruded Material Modeling

Powder metals have been used in Additive Manufacturing (AM) processes such as injection molding, extrusion, and slip casting for decades. Recent innovations in the Fused Filament Fabrication (FFF) have provided the opportunity to mix powder metals with a binding thermoplastic at elevated temperatures to create 3D components. This research attempts to define the rheological characteristics of paste materials used to produce 3D components at room temperature using powder metals that will provide the following three outcomes: material that will flow under low shear stress, green strength to provide structural support of material deposited on top and prevent deformation under gravitational load, and once cured to provide material properties that are comparable to those of materials produced by traditional means. The purpose of this research is to determine if powder metal components can be produced by FFF at room temperature while maximizing the powder metal composition in the mixture.