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Volume 103
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Shi, H., Shan, Z., Yang, H., Yan, D., & Song, W. (2025). Simulation of binder migration behavior and bridge network morphology in frozen sand mold additive manufacturing. Particuology, 103, 286-300. https://doi.org/10.1016/j.partic.2025.06.005
Simulation of binder migration behavior and bridge network morphology in frozen sand mold additive manufacturing
Haoming Shi a c, Zhongde Shan a b c *, Haoqin Yang b c *, Dandan Yan a c *, Weifei Song b c
a College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China
b College of Material Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China
c State Key Laboratory of Mechanics and Control for Aerospace Structures, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China
10.1016/j.partic.2025.06.005
Volume 103, August 2025, Pages 286-300
Received 9 February 2025, Revised 8 May 2025, Accepted 3 June 2025, Available online 14 June 2025, Version of Record 21 June 2025.
E-mail: shanzd@nuaa.edu.cn; yang-haoqin@nuaa.edu.cn; yandandan@nuaa.edu.cn
Highlights

• Migration mechanism of binder droplets in powder bed is explored.

• Parameters affect initial migration behavior of binder in Z direction.

• Pore throat structure guides and constrains the binder migration.

• Binder freezing occurs first at edges and prevents further binder migration.


Abstract

Frozen sand mold additive manufacturing is a new process that utilizes water-based binder phase transition freezing in a low-temperature environment to create sand molds. The aim is to reduce resin binder pollution. However, binder migration and phase transition behavior require further investigation. This study uses CFD method to numerically simulate the droplet size, injection frequency, and environmental temperature in the migration behavior of water-based binder. The results show that changes in process parameters lead to alterations in the binder migration path, which in turn affects the structure of the binder bridge network. The pore throat guides binder migration, leading to a higher concentration of binder near the sand layer surface. At 268 K, the freezing rate of the binder is much faster than the migration rate of the binder during the slow development stage, significantly affecting the migration behavior of the binder and the binder bridge network structure.

Graphical abstract
Keywords
Binder jetting additive manufacturing; Binder migration; Liquid-powder interaction; Binder bridge network; Frozen sand mold
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