Ismail, Joehan Ariff (2025) Investigation of process parameters in thermal debinding of 3D-printed 17-4PH stainless steel samples. Masters thesis, Universiti Teknikal Malaysia Melaka.
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Abstract
The thermal debinding process is a key stage in metal additive manufacturing, significantly influencing the quality and properties of 17-4PH stainless steel components produced using Fused Deposition Modeling (FDM). This study investigates optimal thermal debinding parameters aimed at effectively removing binder materials while maintaining the structural integrity of printed components prior to sintering. Samples were fabricated using Ultrafuse® 17-4PH stainless steel filament on an Ultimaker S5 3D printer, with precise control of printing conditions. The research specifically explored the influence of varying heating rates which were 1.5°C/min, 2.0°C/min and 2.5°C/min and different peak temperatures of 400°C, 500°C, and 600°C, all conducted under a consistent nitrogen atmosphere and without an isothermal holding period. After debinding, samples underwent comprehensive analysis including visual inspection, Scanning Electron Microscopy (SEM), and Energy Dispersive X-ray Spectroscopy (EDX). These methods provided valuable information about surface conditions, internal microstructural features, and elemental distributions. Results revealed at heating rates of 1.5°C/min, combined with peak temperatures of 500°C provided optimal conditions for thermal debinding. SEM analysis demonstrated that samples processed under these conditions exhibited minimal structural defects, such as micro-cracks or bloating, preserving the integrity of the component structure. Furthermore, the SEM images confirmed a homogeneous and well-developed porosity network, essential for efficient binder removal during the subsequent sintering process. In contrast, samples at heating rates 2.5°C/min were found to have a higher incidence of structural irregularities, particularly internal voids and minor cracks. Additionally, EDX compositional analysis highlighted a notable increase in residual carbon content within these samples. Specifically, the EDX results revealed higher carbon concentrations, indicating incomplete removal of binder material and possible accumulation of carbonaceous residues at faster heating conditions which was 2.5°C/min. This could adversely affect the mechanical properties and overall quality of the final sintered components. Overall, the findings underscore the critical importance of carefully balancing thermal debinding parameters. Proper control of heating rates and peak temperatures is essential to optimize both the physical structure and chemical composition of the 17-4PH stainless steel components. This study provides valuable insights and practical guidance for emphasizing that meticulous process control.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Additive manufacturing, Three-dimensional printing\, Stainless steel, Thermal analysis |
| Subjects: | T Technology > T Technology (General) T Technology > TS Manufactures |
| Divisions: | Library > Tesis > FTKIP |
| Depositing User: | Norhairol Khalid |
| Date Deposited: | 18 Aug 2026 08:06 |
| Last Modified: | 18 Aug 2026 08:06 |
| URI: | http://eprints.utem.edu.my/id/eprint/30348 |
| Statistic Details: | View Download Statistic |
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