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John has 12 patents issued or pending and has given numerous invited presentations is published internationally. At Lockheed Martin, he was responsible for developments in advanced polymers, composites, carbon nanotubes, novel titanium production and processing, additive manufacturing of both polymer and metallic systems, and low observable manufacturing methods. His aerospace background includes lengthy positions at Honeywell Engines, where he supported gas turbine advanced technology and was program manager of Marine Engines programs and as senior manager for Manufacturing Exploration and Development at Lockheed Martin Skunk Works. Prior to Arconic, he was Director of the High-Performance Metals Program for the CSIRO, the national science agency for Australia where he oversaw the R&D and commercialization activities and investments in the program’s two principal areas: metal production and additive manufacturing.

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John Barnes is the Founder of The Barnes Group Advisors and was Vice President of Advanced Manufacturing & Strategy at Arconic, where he worked with Airbus to qualify the first titanium additively manufactured parts for series production on the A350. Mostafaei’s research mainly focuses on applying fundamental aspects of materials science and engineering to address the demands of various manufacturing industries via additive manufacturing.ĭr. Mostafaei has published literature in high temperature corrosion and failure analysis of stainless steels and nickel-based superalloys used in petroleum and nuclear power plants, multi-functional organic coatings, welding metallurgy, and nanomaterials fabrication. Effects of print processing optimization during binder jetting as well as post-processing development including sintering and surface treatment of the 3D printed parts were investigated on the microstructural evolution, phase formation, and resulting properties of binder jetted parts. Additionally, he has been working on laser powder bed fusion of metallic materials and evaluation of the processing parameters on the microstructure, porosity distribution, mechanical properties, and corrosion behavior of various additive manufactured parts from titanium, aluminum, stainless steel, and nickel-based alloys. research was primary on binder jet 3D printing of structural, bio-compatible, metal matrix composites and magnetic shape memory alloys. degree in Corrosion and Materials Protection (Sahand University of Technology, Iran). in Materials Science and Engineering from the University of Pittsburgh, PA, USA, a post-doc research fellow at the Manufacturing Futures Initiatives (MFI) Center at Carnegie Mellon University between September 2018 and December 2019 and an M.Sc. Amir Mostafaei is an Assistant Professor in the Department of Materials, Mechanical and Aerospace Engineering at the Illinois Institute of Technology, Chicago, since January 2020, with a Ph.D. Finally, opportunities for future advancement are addressed.ĭr. With the development of AM technologies and the need for post-processing in 3D printed parts, understanding the microstructural evolution during densification is necessary and here, processing steps are explained. Furthermore, to determine the effects of the binder jetting process on metallurgical properties, the role of powder characteristics (e.g., morphology, mean size, distribution), printing process parameters (e.g., layer thickness, print orientation, binder saturation, print speed, drying time), sintering (e.g., temperature, holding time), and post-processing are discussed.

Therefore, a detailed review of the physical processes during 3D printing and the fundamental science of densification after sintering and post–heat treatment steps are provided to understand the microstructural evolution and properties of binder jetted parts. Various powdered materials have been 3D printed, but a typical challenge during BJ3DP is developing printing and post-processing methods that maximize part performance. By taking advantage of traditional powder metallurgy, BJ3DP machines can produce prototypes in which material properties and surface finish are similar to those attained with traditional powder metallurgy. Among AM technologies, binder jetting holds distinctive promise because of the possibility of rapid production of complex structures to achieve isotropic properties in the 3D printed samples. As a non-beam-based additive manufacturing (AM) method, binder jet 3D printing (BJ3DP) is a process in which a liquid binder is jetted on layers of powdered materials, selectively joined, and then followed by densification process.

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