Study on selective laser sintering process and investment casting of rice husk/ Co-Polyamide (Co-PA hotmelt adhesive) composite

Abstract

The current available wood-plastic materials used for selective laser sintering (SLS) investment casting are often poor in fluidity in molten state, which is not easy to flow out the shell mold. This led to a large amount of residual ash in mold after heating and lowered the quality of the sintered parts. In this article, the Co-Polyamide (Co-PA Hotmelt adhesive) and rice husk powders (RH) were proposed as the feedstock of the rice husk (RH)/CO-PA composite (RHPA) for SLS. CO-PA with good fluidity was used as the matrix and RH powder as the additive materials. This paper aims to optimize the SLS processing parameters and determine the optimal ratio of RHPA parts manufactured by SLS. Through this work, an orthogonal experimental method of five factors and four levels was used to determine the optimum SLS parameters for the RHPA SLS test. The scan spacing, scan speed, laser power, layer thickness, and preheating temperature are chosen as main SLS affecting factors of this study. The synthesis weighted scoring methods were used to conclude the optimal combination of SLS parameters of RHPA i.e., scan spacing = 0.15mm, scan speed = 2m/s, laser power =16W, layer thickness = 0.25 mm and the preheating temperature = 74°C. Moreover, the influence of RH content on the mechanical properties, dimensional accuracy, and the residual ash content of RHPA parts was determined. When the ratio of RH powder on RHPA is 10 wt %, the bending strength of the sintered parts will reach 2 MPa. Besides, the residual ash content of RHPA parts after heating step was lower (1.1881%) and the tolerance level is CT5. Thus, the dimensional accuracy in X, Y, and Z directions of 10 wt % RHPA SLS parts is 99.79%, 98.71%, and 97.9%, respectively; and the surface of casting was smooth and clear details.